Lot 1. Task 1: Product definition. European Commission DG ENTR

Transcription

1 European Commission DG ENTR Preparatory Study for Eco-design Requirements of EuPs [Contract N S ] Lot 1 Refrigerating and freezing equipment: Service cabinets, blast cabinets, walk-in cold rooms, industrial process chillers, water dispensers, ice-makers, dessert and beverage machines, minibars, wine storage appliances and packaged condensing units Task 1: Product definition Final Report Contact BIO Intelligence Service S.A.S. Shailendra Mudgal Jonathan Bain +33 (0) shailendra.mudgal@biois.com jonathan.bain@biois.com

2 Project Team BIO Intelligence Service Mr. Shailendra Mudgal Mr. Benoît Tinetti Mr. Jonathan Bain Mr. Raul Cervantes Mr. Alvaro de Prado Trigo Disclaimer: The project team does not accept any liability for any direct or indirect damage resulting from the use of this report or its content. This report contains the results of research by the authors and is not to be perceived as the opinion of the European Commission. The European Commission is not responsible for any use that may be made of the information contained therein. 2 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

3 Contents 1. Task 1: Definition Introduction Refrigeration market diversity Institutional and other actors for standards and legislation EU level MS level Third country standards organisations Other actors Basic concepts of refrigeration Cooling (or refrigeration) load Vapour-compression cycle Absorption cycle Total energy consumption (TEC) Refrigerants Refrigeration systems Efficiency measurement Insulation properties Product definitions Service cabinets General product definition Existing product definitions Product description Functional unit and performance parameter Service cabinet classification and scope for the study Blast cabinets General product definition Existing product definitions Product description Functional unit and performance parameter Blast cabinets classification and scope for the study Walk-in cold rooms General product definition Existing product definitions Product description Functional unit and performance parameter Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 3

4 Walk-in cold rooms classification and scope for the study Process chillers General product definition Existing product definitions Product description Functional unit and performance parameter Chiller classification and scope for the study Remote condensing units General product definition Existing product definitions Product description Functional unit and performance parameter Remote condensing units classification and scope for the study Prodcom definitions Product test standards, their development and other standards Service cabinets EN ISO 23953:2005 (under revision) EN 441 (UK and DK) DE DIN (draft standards in progress) ANSI/AHRI (US) US ASHRAE Standard CAN/CSA-C (R2008) Comparison of volume measurement methods Testing and protocols Blast cabinets EN 328: EN 327: DE DIN 8953/ Walk-in cold rooms Introduction European Technical Approval Guideline (ETAG) 021 and Within the documentation, it states that the assessment of the panels which are main components of cold storage rooms, i.e. composite panels with insulating cores, is primarily based on the draft harmonised technical specifications ETA-Guideline 016 "Self supporting light weight composite panels" or EN "Double metal faced insulated sandwich panels" ( ) EN 14509: BS EN 13165: BS EN : Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

5 Agreement on the international carriage of perishable foodstuffs (ATP) PAS 57: AHRI 1251 (SI) (and AHRI 1250 (I-P)) US test procedures for walk-in coolers and freezers US DOE proposed test procedures for walk-in coolers and freezers Process chillers EN 14511: EN 15218: pren AHRI 550/ ANSI/AHRI CAN/CSA-C AS/NZS 4776: Remote condensing units EN 13771:2003/ EN 13771: EN 13215: ASHRAE Standard ISO/R 916: Standards related to the design, use and safety of products EU EN 631-1:1993 Gastronorm EN 1672:1997 Food processing machinery hygiene requirements EN ISO 14159: EN : EN : FR NF AC D40-003: DE VDMA Operation and use of refrigerated display cabinets DE VDMA Energy efficiency of refrigerating systems US NSF/ANSI 7: Standards affecting the use of refrigerants EU EN 378: DE VDMA Operational requirements for refrigerating systems US ASHRAE Standard Summary of existing standards Service cabinets Blast cabinets Walk-in cold rooms Process chillers Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 5

6 Remote condensing units Existing legislation and voluntary agreements Service cabinets UK ECA incentive scheme for plug-in commercial service cabinets US DOE MEPS US CEC MEPS Canada CAN/CSA-C Energy performance standard for food service refrigerators and freezers Australia/New Zealand refrigerated display cabinets MEPS US Energy Star voluntary programme for commercial solid door refrigerators and freezers US CEE Commercial Kitchens Initiative US AHRI certification programme for commercial refrigerated display merchandisers and storage cabinets Blast cabinets FR commercial food preparation hygiene requirements law of 29/09/ UK Department of Health Guidelines Austrian Hygiene Certificate Guideline Walk-in cold rooms US minimum requirements for walk-in cold rooms and walk-in freezers UK ECA incentive scheme for cellar cooling equipment PQS Quality Assurance protocol E01/CR/FR-VP ATP agreement on the international carriage Process chillers EU EUROVENT certification programme for liquid chilling packages UK ECA incentive scheme for packaged chillers US ASHRAE CAN CSA-C performance standard for packaged water chillers Australia/New Zealand water chillers MEPS Remote condensing units UK ECA incentive scheme for air-cooled condensing units EU environmental legislations European Directive 2002/96/EC on Waste Electrical and Electronic Equipment (WEEE) European Directive 2002/95/EC on the Restriction of the use of certain Hazardous Substances in electrical and electronic equipment (RoHS) Legislation related to refrigerant fluids European Regulation N 2037/2000 on Ozone Depleting Substances (ODS) Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

7 European Regulation N 842/2006 on certain fluorinated greenhouse gases DK statutory order Austria Ordinance No 447/ Norway - Tax and refund scheme for imported HFCs Energy-efficiency and use legislation EuP TREN Lot 13 Legislation related to household refrigerating appliances EuP TREN Lot 11 Electric motors Legislation related to the lighting system Legislations related to tertiary and domestic lighting European Directive on Electromagnetic Compatibility (ECM) 2004/108/EC European Directive on construction products 89/106/EEC Health and safety legislation European Directive 95/16/EC on Machinery, amended by 2006/42/EC European Directive 2001/95/EC on General Product Safety European Directive 73/23/EEC on Low Voltage Equipments (LVD) Pressure Equipment Directive (PED) 1997/23/EC European Directive 98/83/EC on quality of water Hazard Analysis Critical Control Point (HACCP) Summary of temperature and time constraints for cooked foodstuff Other voluntary agreements EUROVENT certification programmes for refrigeration components ASERCOM certification of refrigerant compressors DK demanufacture of refrigeration equipment Summary of existing legislation and voluntary measures Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units Conclusions for Task ANNEXES Annex 1-1: Additional standards related to refrigeration and freezing equipment EN 153: EN ISO 15502:2005 (corrigendum 1:2007) EN 28960:1993 (ISO 8960:1991) ANSI/ARI ANSI/ARI Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 7

8 1.11. ANSI/ARI ANSI/ARI ISO 5149: ATP agreement Introduction Definitions Requirements Test methods and procedures (Annex 1, Appendix 2 of the agreement) Definitions and general principles (Section 1) Insulating capacity of equipment (Section 2) Effectiveness of thermal appliances [applications] of the equipment (Section 3) Procedure for measuring the effective refrigerating capacity of unit when evaporator is free from frost (Section 4) Checking the insulating capacity of equipment in service (Section 5) Verifying the effectiveness of thermal appliances of equipment in service (Section 6) Compliance and enforcement Other related standards Annex 1-2: Summary of data for selection of the Base Cases Annex 1-3: Summary of data for minibars Annex 1-4: Summary of data for wine storage appliances Annex 1-5: Summary of data for dessert and beverage machines General product definition Existing product definitions Product description Functional unit and performance parameter Dessert and beverage machine classification and preliminary scope for the study Annex 1-6: Summary of data for water dispensers General product definition Existing product definitions Product description Functional unit and performance parameter Water dispenser classification and water dispensers included in the scope Annex 1-7: Summary of data for ice-makers General product definition Existing product definitions Product description Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

9 Functional unit and performance parameter Ice-maker classification and ice makers in the scope of the study Annex 1-8: Other information Glossary Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 9

10 10 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

11 1. Task 1: Definition 1.1. INTRODUCTION Task 1 provides a technical description of all products, including the suggested functional unit, and preliminary data on energy consumption. The product definitions are based in particular on definitions available from external sources (e.g. EU trade statistics, existing standards and regulations, voluntary initiatives, the industry, and dictionaries). Key technical parameters impacting the environmental performance of the product are identified as a basis for further analysis in the next steps of the study. Harmonised test standards and additional sector-specific procedures for product-testing are identified and discussed. Finally, Task 1 presents any relevant legislation, voluntary agreements, and labelling initiatives at EU level, in Member States, and in third countries. The Ecodesign Directive (2005/32/EC) is expected to improve the environmental performance of major refrigerating and freezing equipment in the EU through ecodesign. In this context, a first preparatory study (TREN Lot 12 1 ) was conducted during , focussing on refrigerated display cabinets (both remote and plugin), beverage coolers, ice-cream freezers, and cold vending machines. Commercial refrigeration equipment and additional industrial refrigeration equipment, not covered by TREN Lot 12 will be covered by this study, namely: service cabinets; blast cabinets; walk-in cold rooms; process chillers; water dispensers; ice-makers; dessert and beverage machines; minibars; wine storage appliances; and remote condensing units. This study aims at proposing solutions to improve the energy performance of these product categories and reduce their environmental impacts during their lifecycle. As in all Ecodesign preparatory studies, a common and coherent methodology 2 is used to analyse the environmental impact and improvement potential of the products, and ecodesign options are analysed from a life cycle cost perspective. This methodology consists of seven main tasks, conducted in an iterative manner to allow integration of new information throughout the project. 1 BIO Intelligence Service, Ecodesign Preparatory Study TREN Lot 12, Final Report, European Commission (DG TREN), Available at: 2 VHK, Methodology for Ecodesign of Energy-using Products (MEEuP), Final Report, European Commission (DG ENTR), Available at: ec.europa.eu/enterprise/eco_design/finalreport1.pdf Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 11

12 At an interim stage of the project, a matrix of data was developed to prioritise product groups from the list described above. This information was drawn from the literature and stakeholder input, and was distributed to stakeholders for comment. The matrix is described in annex 1-2, and the following product groups were selected in light of their significant potential for improvement through ecodesign and subsequent reduction of environmental impacts across the EU. These product groups were: service cabinets; blast cabinets; walk-in cold rooms; process chillers; and packaged remote condensing units. The information relating to the remaining product groups is summarised in annexes 1-3 to REFRIGERATION MARKET DIVERSITY Refrigeration products covered in ENTR Lot 1 span a large range of applications and the products are used in diverse environments such as supermarkets, restaurants, hotels, pubs, cafés and industrial facilities. These products are estimated to consume a significant proportion of electricity in the EU (as an example, in the UK this is around 3% of total energy consumption and 1% of total greenhouse gas emissions 3 ). Moreover, they may cause other negative environmental impacts during their life-cycle due to their material content, such as refrigerants and insulating agents. When designing such appliances to reduce the impacts related to climate change and global warming, manufacturers usually focus on the energy requirement of the appliance and on the choice of the refrigerant (e.g. HFCs, which are being replaced by alternatives). Many such initiatives for a more environmentallyfriendly design may derive from various sources, such as national and international regulations, financial incentives and manufacturers commitment towards the environment. The end-user, although conscious of the energy performance of these products (as they directly affect their electricity bills), is not always influenced by environmental performance during their purchase decision INSTITUTIONAL AND OTHER ACTORS FOR STANDARDS AND LEGISLATION Standards, legislation (such as Minimum Energy Performance Standards, MEPS) and voluntary agreements related to the products covered by ENTR Lot 1 and discussed in Task 1 have been developed at EU level, in individual MS, and in several third countries. 3 Refrigeration Road Map. An action plan for the retail sector. Carbon Trust, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

13 EU level The approach defined in the European Council (EC) Resolution of May 1985, introduced, among other things, a clear separation of responsibilities between the EC legislator and the European Standards Bodies (CEN 4 /CENELEC 5 ) in the legal framework allowing for the free movement of goods 6 : EC Directives define the "essential requirements", e.g., protection of health and safety, which goods must meet when they are placed on the market. The European standardisation bodies have the task of drawing up the corresponding technical specifications meeting the essential requirements of the directives; compliance with the standard will provide a presumption of conformity with requirements of the directive. Such specifications are referred to as "harmonised standards". European standards European standards, denoted by prefix EN, are adopted by CEN, CENELEC or ETSI and imply an obligation to implement an identical national standard and to withdraw any conflicting national standards 7. Such standards may also be issued by an international standardisation organisation such as the International Organisation for Standardisation (ISO) and the International Electrotechnical Commission (IEC) and are recognised at both the international and EU levels (this includes international standards that have been adopted by European Standards Bodies, for example, EN ISO or EN IEC standards). CEN/CENELEC internal regulations define a standard as a document, established by consensus and approved by a recognised body that provides, for common and repeated use, rules, guidelines or characteristics for activities or their results, aimed at the achievement of the optimum degree of order in a given context. Standards should be based on consolidated results of science, technology and experience, and aimed at the promotion of optimum community benefits. European Organisation for Technical Approvals (EOTA) The European Organisation of Technical Approvals (EOTA), which groups together the national approvals bodies, can draw up technical approvals guidelines in respect of a construction product or family of construction products, acting on a mandate from the Commission and after consulting the Standing Committee on Construction 8, in the context of Directive 89/106/EEC on construction products ( ). European technical approvals are used to assess the suitability of a product for its intended use in cases where there is no harmonised standard, no recognised national standard and no mandate for a European standard and where the Commission feels, after consulting the Member States within the Standing Committee on Construction, that a standard cannot or cannot yet be prepared. 4 European Committee for Standardisation: 5 European Committee for Electrotechnical Standardisation: 6 European Commission website: ec.europa.eu/comm/enterprise/newapproach/standardization/harmstds/index_en.html 7 European Committee for Standardisation: 8 ec.europa.eu/enterprise/sectors/construction/documents/legislation/cpd/index_en.htm Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 13

14 MS level European Federation of Catering Equipment Manufacturers (EFCEM) EFCEM represents manufacturers of commercial kitchen equipment and includes the key European national associations in its membership. The federation is active in the formulation of standards for the industry and through its meetings seeks to identify and act on issues of common interest. EUROVENT certification programme (EUROVENT) The EUROVENT programme is a voluntary minimum performance and labelling scheme which includes components, and products similar to the products within the scope of ENTR Lot 1. Association of European Refrigeration Compressor and Control Manufacturers (ASERCOM) ASERCOM has established a certification scheme for the performance of refrigeration compressors which aims at helping buyers to select their products based on performance criteria. Several EU Member States have also developed relevant standards and legislation which are used internationally, such as France (FR), Germany (DE), Denmark (DK) and the UK. Normes Française (FR NF) In France, the national standards body, NF, develops various standards, including those related to refrigeration and freezing equipment. Verband Deutscher Maschinen- und Anlagenbau (DE VDMA) The German Engineering Federation, VDMA, is one of the key service provider associations in Europe and offers the largest engineering industry network in Europe. It is involved in the development of standards relating to refrigeration and freezing equipment and systems. Enhanced Capital Allowance Scheme 9 (UK ECA) The UK ECA scheme was designed to encourage businesses to invest in energy saving equipment allowing business to claim 100% first year capital allowance in such investments 10. Enhanced Capital Allowances (ECAs) can only be claimed on energy-saving products listed in the Energy Technology List (ETL) that meet the relevant criteria for their particular technology group. Energy using appliances under this program include packaged chillers and commercial service cabinets (plug-in only). The ETL is divided into two parts: the Energy Technology Criteria List which contains details of the energysaving criteria that must be met for each of the technology classes; and the Energy Technology Product List which contains a list of products that have been certified as meeting those standards. 9 ECA website: 10 ECA website: 14 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

15 Market Transformation Programme 11 (UK MTP) The UK s MTP was launched following a consultation paper 12 issued by the Environment & Business Division, in October 1997 and supports the development and implementation of UK Government policy on sustainable products. Domestic or commercial appliances including commercial refrigeration (liquid chillers, service cabinets, cold rooms, cellar cooling equipment, ice-making machines, refrigerated display cases, and refrigerated vending machines). Please see annex 1-8 for more information on this programme Third country standards organisations In the USA, several organisations are involved in the development of standards which are relevant to Lot 1. Air-Conditioning, Heating, and Refrigeration Institute (AHRI) The AHRI is the trade association representing manufacturers of air conditioning, heating, and commercial refrigeration equipment. It also develops industry standards and voluntary certification programs (AHRI performance certification programs) for refrigeration equipment. The ARI standards mainly aim at measuring the energy performance of the refrigeration appliances and of their components. American National Standards Institute (ANSI) The ANSI is the American National Standards Institute that oversees the creation, promulgation and use of norms and guidelines as well as accrediting programs that assess conformance to standards. The ANSI standards mainly aim at enhancing the global competitiveness of U.S. business and the American quality of life 13. American Society of Heating, Refrigerating, and Air-conditioning Engineers (ASHRAE) This association develops standards for refrigeration appliances, heating appliances, ventilation and air conditioning. They are also in charge of promoting sustainability through research, publications and education. US Department of Energy (US DOE) The US Energy Policy Act of 2005 prescribes new and amended energy conservation standards and test procedures that apply to commercial refrigeration equipment. The US Energy Independence and Security Act of 2007, enacted on 19 December 2007, establishes energy conservation standards for certain consumer products and commercial and industrial equipment, including walk-in cold rooms and walk-in freezers. Final responsibility for the appliance of energy standards in policy measures resides with the US DOE. California Energy Commission (US CEC) 11 MTP website: 12 Department of the Environment, Transport and the Regions.Energy Efficient Consumer Products: A Market Transformation Strategy for More Sustainable Consumption, Website: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 15

16 The US CEC adopted the California Appliance Efficiency Regulation, which became effective 29 th December2007. It was reviewed in 2009 and the document CEC was produced. The California Appliance Efficiency Regulation 14 includes energy efficiency levels for the following types of new appliances (within the scope of ENTR Lot 1): automatic commercial ice-makers, refrigerators and freezers with doors (i.e. service cabinets), walk-in refrigerators and freezers, and water dispensers. The Regulation excludes certain refrigeration appliances with a volume exceeding 85 ft 3 (2.4 m 3 ) and automatic commercial ice-makers with a harvest rate lower than 50 lbs (22.7 kg)/24 hours or greater than 2,500 lbs. (1,134 kg)/24 hours. US Energy Star labelling programme Energy Star is a joint program of US DOE and the US Environmental Protection Agency. It is a scheme to promote energy efficiency, through setting minimum performance standards and providing a label to those products that qualify, allowing end-users to identify energy efficient products. Canada Other actors In Canada, the standards organisation involved in standards development is the Canadian Standards Association (CAN CSA). Canadian Energy Efficiency Regulations set technical requirements for various classes of Energy-using Products, including commercial refrigeration under which products are separated into different product categories. Canadian regulations affect products such as chillers, service cabinets, water and beverage dispensers and ice-makers. Australia/New Zealand In Australia and New Zealand, the organisations involved in the development of standards are Standards Australia and Standards New Zealand (AS/NZS). The MEPS programmes are mandatory in Australia by state government legislation and regulations which give force to the relevant Australian Standards. Regulations specify the general requirements for MEPS for appliances, including offences and penalties if a party does not comply with the requirements. Many other actors are involved in the refrigerant market including, for example, those that draft legislation for health and safety (for example, to maintain food quality, maximum refrigeration storage temperatures are defined) and develop voluntary schemes related to maintenance BASIC CONCEPTS OF REFRIGERATION This section aims to facilitate the understanding of refrigeration technology. It introduces the basic refrigeration concepts, provides a description of the two main types of refrigeration cycles used in commercial refrigeration equipment, and the fundamental components required. The design of any cooling appliance follows some basic principles of thermodynamics: 14 Website: 16 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

17 Heat naturally flows from high to low temperature points. Energy in the form of heat is necessary to vaporise 15 a liquid. During an evaporation process, the liquid absorbs heat from its surroundings, thus cooling its surroundings. Contrarily, a substance releases heat to its surroundings during a condensation process 16. The evaporating and condensing temperatures of a substance are correlated with the pressure. If the pressure of a substance decreases, its evaporating and condensing temperature will also decrease Cooling (or refrigeration) load The cooling load (also called refrigeration load) is the total amount of heat that must be removed by an appliance (or a refrigeration system) in order to maintain a desired constant temperature. It is one of the factors that determine the energy consumption of an appliance, along with system efficiency: the lower the cooling load is, or the greater the system efficiency is, the smaller its energy consumption. The cooling load is influenced not only by the desired temperature inside the appliance, but for example by possible heat gains from the external environment and operating components inside the appliance (e.g. fan motors, compressor motor, or lighting). The energy consumption of refrigerator will depend also on the type of foodstuff to be cooled down. Food with highly water content will require more energy to be cooled than lower water content foodstuff. These products tend to have higher specific heat capacities Phase transition from liquid to gas 16 Phase transition from gas to liquid 17 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 17

18 Vapour-compression cycle The vapour-compression cycle is the most widespread technology in refrigeration 18. It is defined as a closed-loop process (see Figure 1-1), in which a refrigerant circulating through a pipe loop is used to remove heat from a product (or area) and discharges it elsewhere. All refrigeration equipment using vapourcompression technology incorporates the following four main components: an evaporator, a compressor, a condenser, and an expansion device. Figure 1-1 : Vapour-compression cycle 19 Some appliances integrate all four components within the product itself and are called plug-in appliances (also known as integrated or self-contained appliances). In contrast, another type of refrigeration equipment includes only the evaporator and the expansion devices, and is known as a remote appliance. Remote equipment is connected to either a packaged condensing unit(s) or a central refrigeration plant containing the compressor(s) and condenser(s) and providing the refrigerating energy, via the refrigerant circuit (pipe loop), to form a remote refrigeration system. Remote condensing units and central plants can serve several refrigerating appliances (see for more details). Most of the appliances in commercial refrigeration present several differences in design and components for low temperatures (negative temperatures) and medium and high temperatures (positive temperatures). Due to these different operating temperatures, some characteristics of the system such as refrigerant liquid, compressor, oil circulator or expansion valves can be designed in different ways for low temperature applications and for medium and high temperature applications. These differences will be further investigated in the Base Cases in Task Absorption cycle The absorption cycle has two closed circuit loops in which the two working fluids are circulated, one for the refrigerant and one for the absorption medium. Similar to a vapour-compression system, an absorption system consists of a condenser, an expansion device, and an evaporator. However, instead of a mechanically operated compressor, it has a thermal unit comprising an absorber and a generator (see Figure 1-2). 18 Nearly all current applications use compression-compression refrigeration technology in IPCC Special Report on Safeguarding the Ozone Layer and the Global Climate System Issues related to Hydrofluorocarbons and Perfluorocarbon, Chapter 4, Refrigeration, Available at: 19 Energy Efficiency Best Practice Programme UK. Energy efficient refrigeration technology the fundamentals. Good Practice Guide Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

19 Figure 1-2: Absorption cycle 20 As the main driver of the absorption cycle is the heat provided to the generator, the absorption technology is used mostly when electricity is unreliable or costly, where noise from the compressor is problematic, or where surplus heat is available. Within the scope of ENTR Lot 1, process chillers and mini-bars are the only products that are sensitive to absorption processes Total energy consumption (TEC) Refrigerants The total energy consumption (TEC) of a refrigeration product is the sum of the refrigeration energy consumption (REC) and the direct energy consumption (DEC): TEC = REC + DEC REC: Refrigeration Electrical energy Consumption. This refers to the share of electricity consumption of the components located outside of the equipment (i.e. the condenser and the compressor) which provide the cooling capacity. DEC: Direct Electrical energy Consumption. This refers to the electricity consumption of the components actually included within the equipment. All substances that exist in liquid and vapour states absorb heat during evaporation and can therefore be used as refrigerants. A refrigerant should evaporate at the required cooling temperature (i.e. at the temperature sought in the evaporator of the refrigerating equipment), at a reasonable pressure, and should be able to be condensed by an available cooling medium at a practical pressure. Commonly used refrigerants in refrigeration applications are the following: HCFCs: Hydrochlorofluorocarbons HFCs: Hydrofluorocarbons HCs: Hydrocarbons Unsaturated HFCs (also known as HFOs or Hydrofluoroolefins) 20 Department of Energy Technology; Royal Institute of Technology KTH. Refrigerating Engineering. Stockholm, Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 19

20 NH 3 : Ammonia CO 2 : Carbon dioxide Refrigerants have widely varying properties and impacts and, due to the significant environmental impact of certain refrigerant types, can be heavily regulated during manufacture, use and disposal. Refrigerants will be assessed in detail in Task 4, covering the above issues, as well as their performance and environmental impact Refrigeration systems As described in , a remote refrigeration system consists of remote refrigerating equipment connected either to packaged condensing unit(s) or to a central plant, via the refrigerant circuit. Refrigeration system components can have a great impact on the performance of refrigeration products, and many have specific standards, tests and specifications to ensure their own quality and performance. Four main configurations exist for remote refrigeration systems: direct expansion system; indirect expansion system or secondary refrigerant loop; distributed system; cascade system with two superposed refrigerant cycles. Absorption based central refrigeration systems are less common, but in principle similar configurations are possible. The only difference would be that the compressor of the vapour-compression cycle is then replaced by the absorber and generator of the absorption cycle. A technical annex to this report, based on literature review and stakeholder consultation, describes the various remote vapour-compression refrigeration systems, analyses their market, and assesses their respective environmental impacts, energy consumption and potential for improvement Efficiency measurement The efficiency or performance of refrigeration systems indicators are normally the relation between the energy input and the cooling capacity (output) or unit of internal storage volume. The units commonly used are 21 : Coefficient Of Performance (COP): defined as the cooling capacity divided by the energy input to the compressor, where higher numbers indicate more efficient equipment. This number does not have a unit of measurement. Energy Efficiency Ratio (EER): this value is defined as the ratio of net cooling capacity (Btu/h 22 ) to the total electricity input watt hour (Wh). Higher values indicate more efficient equipment. 21 Source: BTU/h = 2.931x10-4 kw 20 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

21 Insulation properties Energy Efficiency Index (EEI): used to compare performance of service cabinets per unit of storage volume, this is calculated from the total energy consumption per 48 hours, divided by the net internal volume of the product (kwh/48hrs/m 3 ). The performance of equipment can be also evaluated by the ratio of energy consumption aggregated over a period of time with a characteristic dimension of the equipment or physical capacity (volume) (m 3, litre, and kg). The thermal transmission, or thermal resistance, properties of insulating components can be described using the following factors: Lambda (λ) thermal conductivity factor. This represents the thermal transmission through a fixed thickness of material, in W per metre, considering a one degree temperature difference across the material (λ = W/m.K). In the US, it is known as the "K factor. In the EU producers must declare the aged value, or λ design (also termed lambda 90/90 ). As ageing has a detrimental impact on insulation material, the aged λ value will be greater than direct λ value. U value - thermal conductance factor. This represents the thermal transmission through unit of surface area of a material, in W per square metre, considering a one degree temperature difference across the material (U = W/m 2.K). In the context of buildings it can also represent the overall heat transfer coefficient (an averaged thermal conductance in W/m 2.K), and the terminology used in this context can be the K value. In testing of mobile refrigeration, the terminology used for this factor is K coefficient (an averaged thermal conductance for the insulating box in W/m 2.K) ( ). R value thermal resistance value. This represents the thermal resistance of a material, and is the inverse of the thermal conductance factor, the U value (R = m 2.K/W). The conversion between SI and US units of R-value is 1 h.ft². F/Btu = K.m²/W. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 21

22 1.2. PRODUCT DEFINITIONS This section aims to define the terminology for the products covered in ENTR Lot 1. Firstly, detailed information is provided on the technical description and precise definition for each product category. An initial classification of products is based on their function. This also includes a discussion 23 of the technical features (such as components and design) which play a significant role in the energy consumption and other life-cycle environmental impacts caused by different products. PRODCOM definitions related to commercial refrigeration appliances are then described to evaluate whether or not the product classifications match the database categories, and hence if this information can be added to the market analysis SERVICE CABINETS General product definition Professional service cabinets are designed for the storage, but not the sale, of chilled and frozen foodstuff. A professional service cabinet is a refrigerated enclosure (with a gross internal volume of around 100 to litres 24 ) containing goods which are accessible via one or more doors and/or drawers. The sizes of the products are typically based on the Gastronorm standard (see ) and are used in a commercial environment. Commercial refrigerators and freezers are related to the supermarket sector, whereas professional refrigerators and freezers are related to a different market: restaurants, hospitals, canteens, supermarket (i.e. locations not in direct contact with the public). The main difference is not related to installation environment, but to the user: a commercial refrigerator is used by a customer, and will display produce, while a professional refrigerator is used by trained staff, and will store the produce before use. Hence the terminology professional is inferred when discussing service cabinets in ENTR Lot 1. Frequently existing definitions refer to commercial service cabinets, when in fact professional use of the products is relevant, therefore it is noted that terminology varies for identical products Existing product definitions Below is a list of definitions provided by existing schemes. UK ECA Professional service cabinets have been defined under the ECA scheme Energy Technology List (ETL) as products that are specifically designed to store, but not 23 Such technical analysis will be further detailed in the subsequent Tasks (4-6) for products prioritised in Task Gross internal volume should be differentiated from net (internal) volume gross volume is is defined as the volume within the inside walls of the cabinet without internal fittings and with all doors (and drawers) closed, while net volume is measured using different methodologies, defined with test standards. Please see for further details. 22 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

23 to display, chilled and frozen foodstuffs,however, they are referred to as commercial. The scheme covers three categories of product, as described below. Table 1-1: UK ECA product categories Type Gross internal volume (litres)* Single door commercial service cabinets 400 and 600 (+/- 15%) Double door commercial service 1,300 (+/- 15%) cabinets Under counter and counter commercial service cabinets with solid doors or 150 to 800 (+/- 15%) drawers *Gross internal volume is defined as the volume within the inside walls of the cabinet without internal fittings and with all doors (and drawers) closed. To be considered under the scheme, service cabinets must also fulfil the following criteria: they are designed to store chilled or frozen foodstuffs, whilst maintaining them within prescribed temperature limits; they are fitted with solid-faced lids, drawers or doors that: o are normally kept closed, but can be opened to access the contents; o obscure the contents of the cabinet from view when closed; o enable users to access the contents of any part of the interior without stepping into the refrigerated space; and they are a plug-in type cabinet with an integral refrigeration system (as opposed to remote equipment with remotely located condensing unit). The UK ECA scheme does not include remote type refrigerated service cabinet or display cabinets, or cabinets with transparent doors, even if designed for storage. US Energy Star The Energy Star energy efficiency scheme defines a service cabinet as a refrigerator, freezer, or refrigerator-freezer for storing food products or other perishable items at specified temperatures and designed for use by commercial or institutional facilities. 25 Although the standard refers to commercial use, due to the fact that it refers to storage of foodstuff and solid doors, rather than display and transparent doors, the products are in fact intended for professional use. This scheme distinguishes products on the basis of operating temperature and cabinet design. On the basis of operating temperature, a refrigerator is defined as a cabinet designed for storing items between 0 C and +4 C and a freezer refers to a cabinet designed for storing items below 0 C. A refrigerator-freezer is defined as a cabinet comprising more than one compartment, at least one of which is a refrigerator and at least one of which is a freezer. 25 US Energy Star program requirements for commercial sold door refrigerators and freezers: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 23

24 These products can then be classified on the basis of cabinet design: reach-in: an upright commercial, self-contained refrigeration cabinet with hinged, solid doors. horizontal: an upright commercial, self-contained refrigeration cabinet with or without a worktop surface which has hinged, solid doors. roll-in or roll-through cabinet: an upright, self-contained commercial refrigeration cabinet with hinged, solid doors that allows wheeled racks of products to be rolled into or through the refrigerator or freezer. pass-through cabinet: an upright commercial, self-contained refrigeration cabinet with hinged, solid doors on both the front and rear of the refrigerator or freezer. That said, the Energy Star scheme does not differentiate minimum performance standards by these categories. The scheme differentiates by size, operation temperature and product orientation (vertical and chest), and includes remote type refrigerated service cabinets only Product description Service cabinets are closed cabinets designed for the storage of foodstuffs and that have at least one door, drawer or lid. Different configurations are available on the market and some are shown in Figure 1-3. They are largely used in foodservice establishments, such as restaurants, hotels and cafeterias. A very small fraction of professional service cabinets contain glass in their doors, drawers or lids (as opposed to commercial service cabinets that display food and hence frequently incorporate glass) 26. If the operation temperature is below 0 C, the unit is called a freezing service cabinet, whereas when operation temperature is equal to or above 0 C the unit is known as a refrigerated service cabinet. Some service cabinets may have a design in which there are two or more compartments operating at different temperatures, one above 0 C and the second one at temperatures below 0 C. Analysis based on major EU manufacturers catalogue data, existing definitions presented above, and previous studies on commercial refrigeration, shows that the majority of service cabinets rely on compression technology (approximately 99%) and are mostly plug-in appliances (approximately 98%): i.e. all components supporting the refrigeration cycle are included in the cabinet 27. More detailed data on the market composition is provided in Task Source: Foster 27 Source : replies to the 1st ENTR Lot 1 stakeholder questionnaire 24 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

25 Figure 1-3: Configurations of service cabinets The majority of the market is for chilled or frozen upright cabinets with one or two doors (between 400 and 600 litres for single door cabinets and 1,300 litres for double door cabinets) or horizontal units with up to four doors (150 to 800 litres). According to stakeholder feedback and product technical specifications, the energy consumption for service cabinets varies depending on their function and size, but an average product of 600 litres gross might consume 2000 kwh per year 28, while a freezer service cabinet of the same internal volume could consume approximately double to triple this figure. Stakeholders stated that the dominant model is an upright plug-in refrigerator, of approximately 600 litres. Table 1-2: Specifications of service cabinets Operation Number of doors Approx. net volume, Configuration temperature / drawers / lids V (litres)* < V < 700 Refrigerator < V < 1500 Vertical < V < 700 Freezer < V < 1500 Horizontal Chest Freezer < V < 800 Refrigerator < V < 800 Freezer < V < 800 *Measured according to EN 441 The size of this equipment is often based on the Gastronorm standard sizes (see ) Functional unit and performance parameter The function of a service cabinet is to maintain products contained inside the refrigerated space at a temperature below a pre-determined maximum, under specific conditions (climate classes). The energy consumption under these 28 Source: Electrolux Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 25

26 conditions is measured then this value is related to the internal net volume of the machine (energy efficiency index). The functional unit for service cabinets is a unit of storage volume (litres), maintained at a specified temperature. The primary performance parameter is defined as the electricity consumption per unit of storage volume in kwh/litres/year Service cabinet classification and scope for the study A classification is proposed for service cabinets to be included in the scope of the study and is illustrated below. Vertical Horizontal 1-door 4 2-door (or more) 4 1-door 4 Refrigerators Open-top preparation counter 2 out of scope 2-door (or more) 4 Service cabinets 1 Freezers Vertical Horizontal Chest 3 as for vertical refrigerators as for horizontal refrigerators Refrigeratorfreezers Vertical Horizontal as for vertical refrigerators as for horizontal refrigerators 1 Professional products, either plug-in or remote 2 Also known as saladettes, this product configuration is not included in the scope of ENTR Lot 1 due to different functionality 3 Freezers and 1-door only 4 Or with a combination of drawers Figure 1-4: Service cabinet classification This is based on stakeholder feedback and the similarities in definitions specified in the product description summaries above (UK ECA 29 and US Energy Star). Both remote (although rare) and plug-in service cabinets are included in the scope of the present study. Some stakeholders stated that the scope of the product group covered should exclude equipment with glass doors, drawers or lids, and that almost all professional service cabinets have only solid doors (glass doors for commercial service cabinets are covered in TREN Lot 12, but not those in professional service cabinets). With the recent distinction in terminology in ENTR Lot 1 between professional and commercial service cabinets, the exclusion from ENTR Lot 1 of 29 Source: ECA Energy technology criteria list 2009 Refrigeration equipment. Commercial service cabinets Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

27 professional service cabinets with glass doors, drawers or lids could create a loophole in regulation. Open-top preparation tables are considered out of scope, as they are usually distinguished as a different product in standards definitions, and stakeholders commented that their functionality (they have openings in the product shell to cool storage trays, provide short-term storage and have frequent door openings they are also often not based on Gastronorm sizes) varies from service cabinets (which is sealed equipment, providing longer-term storage and with fewer door openings). In addition, they often include features that can impair refrigeration efficiency, e.g. they can offer a base for the end-user to add a char-grill, griddle or grilling top 30. The following table describes some of the main differentiating criteria related to the product group, which may impact on energy consumption. Table 1-3: Specifications of service cabinets Categorisations Explanation Notes Operation Temperature Climate class Volume Configuration Location of condensing unit Differentiating technical and refrigerant requirements at low freezing and high/medium refrigeration temperature The climate class reflects the ambient conditions, which can influence the choice of the refrigerant, as well as the performance Fairly standard sizes, with some variability, based around modular units Vertical, horizontal, chest Reach-in, roll-in and pass-through options Preparation counters Plug-in, remote condensing unit or remote central plant Temperature will influence energy consumption, which will be higher for freezing compared to refrigeration - Size ranges linked to configuration Evidence that relationship with energy efficiency is non-linear Open service counters such as pizza preparation tables with refrigeration units may be considered for exclusion due different functionality. Influences ambient temperature - climate zones (air-on temperature) northern/southern EU relevant for remote Number of doors Door type Drawers Condenser type Refrigerant Glass Can be a variety of combinations, usually based around modular units. Solid or transparent Some horizontal include drawers, based around modular units Water, air, evaporative The choice of refrigerant depends on the operation temperature, ambient temperature, refrigeration system type Rarely used Remote type very rare - Transparent covered in TREN Lot 12 as display cabinets Door-type model could be used as a proxy for calculating energy consumption Stakeholder feedback has determined that most of the market is air cooled The most commonly used refrigerants are R134a and R404a Although rarely used, glass has a much greater U-value, hence its use 30 Source: Foster Refrigeration Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 27

28 will increase thermal infiltration and increase heat load on the refrigeration system BLAST CABINETS General product definition Blast cabinets use a blast of cold air to bring down the temperature of hot food rapidly so it can be stored safely avoiding bacteria growth, and can be chilled or frozen Existing product definitions California Energy Commission (CEC) According to CEC Appliance efficiency Regulations 31 (CEC ), blast cabinets, otherwise named blast chillers, are defined as machines that are able to decrease foodstuff s temperature from +140 F to +40 F (+60 C to +4 C) within 4 hours. However, the regulation does not go into further detail for this definition since this kind of appliance is not included within its scope. FR AC D The Equipment for collective restaurant refrigerating equipment. General design and construction rules for ensuring hygiene in use defines blast equipment as appliances which are used to rapidly decrease the temperature of foodstuff below +10 C in the case of chilling and below -18 C in the case of freezing. They exist in different configurations, only chilling, only freezing and a combination of the two Product description Blast cabinets are similar in construction to service cabinets. However, they rely on relatively larger refrigeration systems in comparison to service cabinets, some even using up to two compressors per cabinet. Blast cabinets also contain additional fans which blast cold air over food to cool it rapidly. A typical blast refrigerator is shown below in Figure 1-5. Under the scope of this study, blast walk-in rooms and continuous-process blast equipment will not be included. For both machine types, the use patterns differ from those of blast cabinets. 31 Source: California Energy Commission Appliance Efficiency Regulations. CEC Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

29 Figure 1-5: Typical blast refrigerator/freezer In the market, there exist other configurations of blast equipment. These are referred to as pass-through and trolleys units. In this case, cars or trolleys are used to organise the foodstuff before it goes into the equipment. The capacity of this equipment is higher, but, as was mentioned by stakeholders, their efficiency is lower because of their need to cool down the trolley itself, among other reasons. Glass-door equipment has not been identified in industry catalogues. All fresh food products contain a natural bacterial load which, under favourable ambient conditions (temperature and humidity), multiplies, increasing the risk of illness and cross contamination with other food. The most dangerous temperature range occurs between +35 C and +65. Blast cabinets are designed to lower the temperature at the centre of the pre-cooked food product as quickly as possible, to avoid prolonging the period at which food temperature is within this range. This not only prevents bacterial load from reaching dangerous levels, it also prolongs the shelf-life of the product. Energy efficiency is therefore not often a priority for the average product. 32 The increase of energy consumption is not linear with the capacity. For larger sizes of equipment, more non-foodstuff material will require cooling as well, and hence, the efficiency decreases. An approximate relation between size and energy consumption is shown in the table below. Table 1-4: Energy consumption per equipment capacity for chilling and freezing cycle reach-in (R) configuration 33 Size Number of trays (GN 1/1) Average food stuff capacity (kg) Approximate energy consumption (kwh/chilling cycle) Approximate energy consumption (kwh/freezing cycle) Small R Medium R Large R Extra-large R > 16 > 48 > 6 > 9 Note: average capacity per GN 1/1 tray: 3-3.5kg of foodstuff The size of equipment trays is normally determined according to Gastronorm standard sizes (see ). It is estimated that each GN 1/1 tray has a capacity of 3 to 3.5kg of foodstuff (as referred in NF AC D40-003, see $ ). The size classification for trolley using equipment (roll-in and pass-through) is given in Table 1-5 below. Table 1-5: Size description of trolley (T) equipment (roll-in and pass-through) Size Number of trays (GN 1/1) Trolleys Average food stuff capacity (kg) 32 Based on brochures and direct feedback of stakeholders 33 Stakeholders feedback Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 29

30 Small T Medium T Large T Testing of blast cabinets has limitations regarding the amount of food that has to be cooked and heated. Stakeholders stated that a limitation of 60kg of foodstuff as maximum quantity to be processed and tested. Limitations are related to the cooling process itself and costs of the process Functional unit and performance parameter The functional unit for blast cabinets can be defined as one kg of food (referred to in this case as the testing material specified in NF AC D ) cooled in a specific cycle (kg/cycle) occupying a specific volume; the cycle defining the temperature change and duration of cooling. The use of mashed potatoes as referred in NF AC D would overcome the problems of heat resistance typical of other measurement loads, as stated by stakeholders. Also, the reason why considering only the mixture of mashed potatoes is to harmonize the material, as other foodstuff specific heat capacity can change the results. The performance of blast cabinets can therefore be defined as the net weight of foodstuff that the cabinet can cool down at a certain temperature within a certain period of time in certain conditions (e.g. ambient conditions, operating conditions). The primary performance parameter can therefore be defined as the electricity consumption per unit of foodstuff (referred to the testing material as per NF AC D ) refrigerated/frozen weight in kwh/kg within the fixed cooling or freezing cycle. Typical operating cycles include 34 : Cooling cycle: 90mins to 110mins for a specified mass of food (normally the manufacturer s declared unit capacity) with starting temperatures ranging from +60 C to +90 C and finishing temperatures ranging from +2 C to +10 C, satisfying European food safety standards and regulations. Freezing cycle: 240mins for a specified mass of food (normally the manufacturer s declared unit capacity) with starting temperatures ranging from +60 C to +90 C and finishing temperatures ranging from -10 C to - 20 C, satisfying European food safety standards and regulations. Many appliances will sound an alarm to signal that the cooling/freezing cycle has finished and then continue to maintain the final temperature for the food, essentially operating then as a service cabinet until the operator removes the food. These appliances are available both in plug-in and remote configurations. For plug-in blast refrigerators/freezers, the electricity consumption is straightforward to assess: it is the total amount of electricity consumed by the appliance. 34 Figures based on product technical specifications and existing product definitions 30 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

31 Remote blast refrigerators/freezers (i.e. units where the compressor and the condenser are located outside the appliance) operate within a broader system. Therefore, the following should be distinguished: the electricity consumption of the remote blast cabinet itself (containing only the evaporator and the expansion device); the electricity consumption arising from the remote system (condensing unit and piping system), to which the blast cabinet is connected, and which delivers the refrigerating energy. This remote system may serve several refrigerating appliances. Currently there is no standardised way of calculating the electricity consumption of remote blast cooling devices. However, the ISO related to remote display cabinets can provide insights for developing a possible method. In the ISO standard on refrigerated display cabinets, the energy consumption is given by the total energy consumption in kilowatt hours per 24- hour period (TEC). The means to calculate TEC for remote refrigerated display cabinets is discussed in Blast cabinets classification and scope for the study This section provides a classification for blast cabinets to be included in the scope of the study. Blast cabinets are produced according to the final operation temperature required and the time to reach this requirement and the capacity of food (by weight) that they can cool in this time 35 as well as the overall orientation of the product (reach-in, roll-in and pass-through). Roll-in/trolleys 1 as below Freezers 2 as below Blast cabinets Cabinets/reach-in Refrigerators 2 Capacity 3 Plug-in Remote Refrigerator / freezers 2 as above Pass-through as above 1 Small Roll-in equipment is can be found in Plug-in configuration (normally up to 60kg or 90kg), bigger units in remote configuration 2 For large equipments (from around 60kg or 90kg) remote configuration represents 90% of sales 3 Lower capacities correspond to reach-in equipment, being from 3kg to 100kg. Pass-though and roll-in equipment capacity varies from around 30kg to 240kg (described in Table 1-4 and Table 1-5) Figure 1-6: Blast cabinet classification Figure 1-6 illustrates the categorisation for blast cabinets including the main energy influencing parameters. Blast cabinets are characterised first by the structure of the equipment (roll-in, cabinet or pass-through), then by the 35 Source: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 31

32 operation temperature (chiller, freezer or chiller-freezer), and finally by capacity (kg, m 3, etc). If required, they can also be characterised by the location of the condensing unit in the arrangement (plug-in or remote either packaged remote or connected to a central plant). Table 1-6: Specifications of blast cabinets Categorisations Explanation Notes Capacity Configuration Operation temperature Climate class Location of condensing unit Condenser type Refrigerant Technical specification and energy will depend on the capacity of the equipment. It can vary from 3kg to 100kg in the case of reach-in equipment or from 30kg to 240kg in the case of trolley equipment Roll-in equipment and pass-through are typically larger appliances than reach-in European equipment is typically used in for a chilling function. Its energy consumption is lower than equipment in freezing operation Freezing equipment has almost been phased-out in some markets, but is still in production in others. Chilling/freezing (combination models). Several stakeholders estimate that this equipment is rarely used in freezing cycles; however, their energy consumption is similar to a freezer in this function The climate class reflects the ambient conditions, which can influence the choice of the refrigerant, and the performance as well Plug-in, equipment with integral condensing unit Remote, connected to a central plant or exterior condensing unit. Water (rarely found), air, evaporative (rarely found) The choice of refrigerant depends on the operation temperature, ambient temperature, refrigeration system type Since safety requirements demand a specific target temperature in a specific time, the unit will consume more or less energy according to the load Larger equipment is less common in the market Roll-in and pass-through energy efficiency is generally lower than reach-in. However this is compensated by the fact that most trolley equipment is remote Energy consumption testing will be influenced by the ambient conditions, and the functioning of the equipment Arrangement to be considered within the testing methodology Two main climate zones could be distinguished in the EU-27: around +11 C for northern Europe and around +15 C for southern Europe Influences ambient temperature - climate zones (air-on temperature) northern/southern EU relevant for remote Stakeholder feedback has determined that most of the market is air-cooled The most commonly used refrigerants is R404a Both remote condensing and plug-in blast cabinets are included in the scope of the present study. While stakeholder estimates predict that a great majority (85%) of the market is dedicated to plug-in blast cabinets, remote condensing units are still considered a subcategory of blast cabinets in this study. 32 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

33 Typically, blast cabinets are sold to consumers according to the final operating temperature required, the time to reach this requirement and the capacity of food (by weight) that they can cool in this time 36. Classification beyond these parameters could be done by type of condensing coolant used (water, air, evaporative), however stakeholder feedback has determined that this is not relevant as most of the market is air cooled WALK-IN COLD ROOMS General product definition According to the definition provided in the International Dictionary of Refrigeration, a cold room is a room or cabinet maintained by a refrigerating system at a temperature lower than ambient temperature. Walk-in cold rooms are insulated rooms that provide refrigerated storage for a variety of items (mainly foodstuff, but also flowers, etc.). They may exist as refrigerators or freezers. Walkin cold rooms with both a refrigerating and freezing compartment are normally referred to as dual compartment and have two separate refrigeration systems Existing product definitions UK Defra According to the UK Defra, a walk-in cold room is defined as follows: A walk-in cold store is an insulated enclosure with similar operational principles to any refrigerator, but capable of storing significantly more goods. Generally, they are fabricated on site and are a customised product, although the prefabricate market is growing in size. Refrigeration is delivered through a forced-air evaporator located in the cooled space, coupled to a condensing unit located externally. EU EOTA The EOTA s definition, presented in the European Technical Approval (ETA) and implemented by the European Technical Approval Guidelines 021 (ETAG 021) for cold rooms covers prefabricated cold storage room kits and cold storage building enclosure and building kits. According to ETA, kits within the scope are those constructed with insulating panels (sandwich type with insulation core) designed to perform store products at temperatures from below +15 C to above -40 C. Under appropriate maintenance a walk-in cold room kit should last 10 years. US DOE The US statutory definition of walk-in coolers and freezers: The terms walk-in cooler and walk-in freezer mean an enclosed storage space refrigerated to temperatures, respectively, above, and at or below 32 degrees Fahrenheit [0 C] that can be walked into, and has a total chilled storage area of less than 3,000 square feet. [(42 U.S.C. 6311(20)(A))] The definition excludes: 36 Source: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 33

34 products designed and marketed exclusively for medical, scientific, or research purposes. [(42 U.S.C. 6311(20)(A))] The definition excludes: products designed and marketed exclusively for medical, scientific, or research purposes. [(42 U.S.C. 6311(20)(B))] US CEC CEC through the 2009 Appliance Energy Regulation 37 (CEC ) establishes the definition for walk-in coolers and walk-in freezers, differentiating units with and without transparent, doors as follows: Walk-in coolers means an enclosed storage space refrigerated to temperatures above 32 F [0 C] that can be walked into and has a total chilled storage area than square feet. Walk-in coolers do not include products designed and marketed exclusively for medical, scientific, or research purposes. Walk-in freezer means an enclosed storage space refrigerated to temperatures at or below 32 F [0 C] that can be walked into and has a total chilled storage area of less than square feet. Walk-in freezer does not include products designed and marketed exclusively for medical, scientific, or research purposes. Natural Resources Canada Natural Resource Canada Office of Energy Efficiency defines walk-in cold rooms as: Walk-in refrigerators and freezers commonly used in fast-food and other restaurants, institutional kitchens, convenience stores and other businesses are room-sized insulated compartments, typically between 7 and 23m 2 of floor area, 2.4m high, and refrigerated by a self-contained system. Much larger refrigerated rooms are used in large supermarkets and food processing and packaging plants, but these are usually supplied by large central refrigeration systems. 38 It therefore only considers plug-in walk-in cold rooms Product description Walk-in cold rooms have at least one door that is large enough to allow a person to go inside the insulated compartment. The main purpose of walk-in cold rooms is for temporary storage of refrigerated or frozen perishable products. They are widely used in restaurants, hotels, convenience stores, food wholesalers, florists and warehouses. Walk-in cold rooms can either be located indoors (i.e. constructed within a building as part of that building) or outdoors (fabricated as a stand-alone structure or an extension of an existing building). For external installations weather-proofing must be considered, such as resistance to: wind load, snow load, rain, direct sunlight, effect of potentially corrosive atmospheres, among others. A typical walk-in cold room consists of following elements: 37 California Energy Commission Appliance Energy Regulation. CEC , August Natural resources Canada, Office of Energy Efficiency. Available at: ttp://oee.nrcan.gc.ca/industrial/equipment/commercial-refrigeration/index.cfm?attr=24 34 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

35 an insulated enclosure, the refrigerated storage space being accessible via an insulated door; a condensing unit located external to the refrigerated storage space; an evaporator fan-coil located within the refrigerated storage space (usually situated near the ceiling in the room), which may or may not be integrated with the condensing unit; and a system of pipes and controls to allow the refrigeration circuit to cool the storage space.the insulated enclosures are constructed from self supporting, prefabricated, insulation panels. These panels are made of two steel skins that are injected with high pressure, often polyurethane, foam. Analysis based on major EU manufacturers catalogue data, existing definitions 39, and previous studies 40 on commercial refrigeration shows that walk-in cold rooms use vapour-compression technology. Further, walk-in cold room refrigeration systems (condensing unit plus evaporator unit) can be found in different configurations. Remote refrigeration systems: evaporator coil within the insulated box, connected to a condensing unit located remotely (i.e. condensing unit located outdoors). Products can also be connected to a central refrigeration system where the condensing unit serves many different refrigerating appliances (e.g. in supermarkets where cooling energy is provided by a refrigeration plant to several appliances including not only the cold room but also, for example, display cabinets) - see Figure 1-7. Figure 1-7: Typical walk-in cold room and major components 41 Packaged refrigeration systems : include all required elements (evaporator fan-coil, condensing unit, and piping) and are either integrated or attached (such as the monoblock type) to the walk-in cold room insulated box, forming part of the product (see Figure 1-8). 39 Source: UK Enhanced Capital Allowance scheme, US Energy Star Program 40 Arthur D. Little Inc, Energy Savings Potential for Commercial Refrigeration Equipment, US DOE, 1996 and Mark Ellis & Associates, Self-Contained Commercial Refrigeration, Australian Greenhouse Office, 2000 and Mark Ellis & Associates, Remote Commercial Refrigeration, Australian Greenhouse Office, Natural resources Canada, Office of Energy Efficiency. Available at: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 35

36 Figure 1-8: Typical Walk-in cold room with packaged refrigeration system If the operation temperature is below 0 C, the unit is called a walk-in freezer, whereas if the operation temperature is equal to or above 0 C the unit is known as a walk-in refrigerator. Some walk-in cold rooms may have a design in which there are two compartments operating at different temperatures, one above 0 C and the second one at temperatures below 0 C. Estimates of walk-in cold rooms integrating glass windows and/or doors sold in the EU range from 1 to 5% of the market 42. These can include in-store products with one or more sides facing the store for display and providing direct rear access to display cases within the store. There is a lack of data describing typical electricity consumption of walk-in cold rooms, but indicative figures of 14,600kWh/year for a 48.31m 3 walk-in refrigerator, and 15,600 kwh/year for a 13.4m 3 walk-in freezers 43, have been identified Functional unit and performance parameter The function of walk-in cold rooms is to store a certain volume of foodstuff at a desired temperature. The functional unit for walk-in cold rooms can be defined as a unit of internal volume maintained at a specified temperature, for a specific period of time, in specific ambient conditions. The functional unit for walk-in cold rooms is a unit of net internal volume (m 3 ), maintained at a specified temperature. The primary performance parameter is defined as the electricity consumption per unit of net internal volume in kwh/m 3 /year. Electricity consumption for plug-in units is straightforward to assess. In the case of remote units connected to a refrigeration system, energy consumption could be assessed as explained for service cabinets Walk-in cold rooms classification and scope for the study Apart from the distinctions drawn in on the operation temperature and refrigeration system type, other examples of potential classification are now considered. Various operation temperature ranges for different applications are described in Table 1-7Error! Reference source not found.. 42 Source: Smeva, GR Scott 43 US Department of Energy, 2009 US DoE. Available at: www1.eere.energy.gov/buildings/appliance_standards/commercial/pdfs/wicf_framework_publicmt g_slides.pdf 36 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

37 Table 1-7: Walk-in cold rooms application temperature ranges 44 Type of equipment Operation temperature ( C) Main use Cellar rooms +10 to +12 Beer cooling, food preparation area General purposes +1 to +4 Generic foodstuff storage Meat rooms -2 to +2 Meat storage Deep freeze -22 to -18 Ice cream storage and other deep-frozen foodstuff An alternative classification classification for walk-in cold rooms based on the size of the equipment is described in Table 1-8. Table 1-8: Walk-in cold rooms categorisation 45 Equipment type Size (m 3 ) Small < 20 Medium 20 < 100 Large 100 < 400 COSP: Coefficient of system performance Storage Average COSP temperature Refrigeration 1.84 Freezing 1.32 Refrigeration 2.41 Freezing 1.47 Refrigeration 2.66 Freezing 1.47 A third classification for walk-in cold rooms, based on the size of the room and configuration of the refrigeration system, is described in Table 1-9. Equipment type Table 1-9: Walk-in cold rooms categorisation 46 Typical (attached refrigeration Size (m 3 ) system) equipment characteristics Nominal capacity (W at +5 C) Mini < 27 2,250 Packaged unit Plug-in Small < 72 4,100 Medium Large Medium condensing unit Centralised plant or large condensing unit Remote < 144 9,000 < ,400 Larger walk-in cold rooms are typically bespoke projects constructed in-situ with component parts from various sources to match the specifications of the end-user (henceforth termed customised ), while smaller rooms are typically constructed from pre-fabricated insulated enclosures (henceforth termed factory-built ). The following classification, adapted from those above and informed by stakeholder feedback, is proposed for walk-in cold rooms. 44 Source: Equipment installer 45 UK MTP estimates 46 Mark Ellis, Strategies to increase the energy efficiency of non-domestic refrigeration in Australia & New Zealand, 2009 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 37

38 Cold stores Wander-in / Logistics stores 2 High temperature (Refrigerators) out of scope Factory-built 3 Customised 4 Integral Monoblock Remote condensing unit Walk-in cold rooms 1 Low temperature (Freezers) as above Remote central plant Dual compartment (Refrigerator-freezers) as above Size 1 Products up to 400m 3 2 Cold stores above 400m 3 in size, or those forming part of a building, or those as a stand-alone external building, or those incorporating loading bays are not covered in ENTR Lot 1 3 Products that are pre-designed and supplied in modular series 4 Designed and constructed by specialist installers Figure 1-9: Classification for walk-in cold rooms There are three main options for the refrigeration system configuration: packaged, remote condensing unit and remote central plant, as described in There are certain products that are excluded from the scope, including products designed and marketed exclusively for medical, scientific, or research purposes; due to tighter temperature control requirement they have a different functionality, which will have an impact on testing and energy consumption. The scope covers only walk-in products and not cold stores (which are more complex constructions). Large systems over 400m 2 are therefore excluded; there would be smaller cold air spill from the product when its door is opened and there are likely to be other heat loads such as vehicle loading bays. Those products incorporated into a building are excluded (apart from cold storage building kits) as they are already covered by existing regulations and are a not similar type of product. The table below describes factors that are important in the consideration of product design, functionality and performance. Table 1-10: Specifications of walk-in cold rooms Categorisations Explanation Notes Small, medium and large products At approximately 100m 2, a loading dock might be included in a walk in cold store these have other sources of heat that should be considered; rooms with loading docks are considered out of the scope due to different functionality Construction Classification should note if the unit is prefabricated or constructed as part of the building 400m 3 too big to be classified as walk-in cold rooms. Rooms constructed as part of a building, or that are over 2.5m in height are considered out of the scope due to different functionality 38 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

39 Categorisations Explanation Notes Configuration Operation and ambient temperatures Climate class Location of condensing unit Packaged (refrigeration system manufactured as a complete product by manufacturer or integrated into one of the panels) or customised (designed individually) Differentiating technical and refrigerant requirements at low freezing and high/medium refrigerating temperature The climate class reflects the ambient conditions, which can influence the choice of the refrigerant, as well as the performance Integrated as part of the insulated enclosure, remote condensing unit or remote central plant Condenser cooling Air-cooled or water-cooled - Application Internal space arrangement Foodstuff / pharmaceutical application; Logistics and large industrial applications vs. small retail and storage uses The internal space arrangement can vary according to requirement of the customer Insulation thickness This can range from 50mm to 180mm - Condenser type Refrigerant Water, air, evaporative The choice of refrigerant depends on the operation temperature, ambient temperature, refrigeration system type Could differentiate between products testable under a test standard, and those more complex products that require a different regulatory mechanism (i.e. unique field-erected designs) The functioning temperature will influence the heat load and energy consumption, which will be higher for freezing compared to refrigeration Two main climate zones could be distinguished in the EU-27: around +11 C for northern Europe and around +15 C for southern Europe Heat rejection process is different between remote and plug-in configurations System performance is influenced by the ambient temperature - climate zones (air-on temperature) northern/southern EU relevant for remote Equipment for pharmaceutical storage is similar but has more narrowly controlled temperatures, stability specifications and stricter build specification (they use a double freezing system; rooms with these more accurate/double refrigeration systems are considered out of the scope due to different functionality Affects performance through change of the internal air flow Stakeholder feedback has determined that most of the market is air cooled The most commonly used refrigerants is R404a Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 39

40 PROCESS CHILLERS General product definition According to the International Dictionary of Refrigeration 47, a chiller is a piece of equipment designed to cool water for air-conditioning plants or units in commercial and industrial processes. In general, a chiller is a refrigerating machine that removes heat from a liquid through a vapour compression or absorption cycle. Chillers can be used in a wide range of applications 48 : Plastics: during plastics manufacturing, these equipments are used to cool hot plastics being injected, blown, extruded or stamped, as well as the equipment used during these processes. Injection moulding: while removing heat from a source e.g. during manufacture of plastic products chillers can transfer heat to make the processes more efficient moulding stage. Printing: chillers are able to remove the heat generated by the friction of the rollers and for cooling down the paper after the ink drying process. Laser: chilling systems are used to cool down laser and power supplies in the laser cutting and light projection industries. Rubber: during the different process of rubber production, temperature control is very important; the use of chillers is common to control these conditions. Air conditioning: commonly used in comfort appliances to remove heat from buildings. These machines are considered within the upper operation temperature range. Equipment working in this temperature range will not be included in this preparatory study, instead they will be analysed within the scope of ENTR Lot 6. Magnetic resonance imaging: chillers can remove heat from scanners if necessary. Anodising: chillers are used to cooled down the water used in these processes to increase the efficiency in warmer climates. Refrigeration systems that remove heat from foodstuffs in order to preserve it can beneficiate from chiller technology. The temperatures reached in these appliances must meet requirements for food preservation Existing product definitions EUROVENT certification programme The EUROVENT certification programme defines liquid chilling packaged as: a factory assembled unit, designed to cool liquid, using a compressor, an evaporator and an integral or remote condenser and appropriate controls. The certification 47 International Institute of Refrigeration. International Dictionary of Refrigeration Source: 40 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

41 programme applies to standard chillers used for air conditioning and for refrigeration. They may operate with any type of compressor, but only electrically driven chillers are included. All refrigerants are considered. Chillers may be aircooled, water cooled or evaporative cooled and with remote condenser. Reverse cycle chillers are also included and certified both in cooling and in heating mode (see ). The UK Defra uses the same definition and specifies that Packaged chillers are commonly used in both central plant air-conditioning systems for the built environment where typical applications include offices, retail, commercial and public premises, and for other process cooling applications including; food & drink manufacturing, the chemical industry, plastics injection moulding and engineering to name but a few. UK ECA The UK ECA scheme defines packaged water chiller functionality as: Packaged chillers generate chilled water that can be used to provide space cooling in summer in large air-conditioned buildings. They can also be used to generate chilled water or brine needed by industrial process cooling. Reversed cycle packaged chillers are able to provide space heating in winter, as well as space cooling. US AHRI 550/ The AHRI 550/ standard for water-chilling packages using the vapour compression cycle defines water chillers as follows: Water-Chilling Package is a factory-made and prefabricated assembly (not necessarily shipped as one package) of one or more compressors, condensers and evaporators, with interconnections and accessories, designed for the purpose of cooling water. It is a machine specifically designed to make use of a vapour compression refrigeration cycle to remove heat from water and reject the heat to a cooling medium, usually air or water. The refrigerant Condenser may or may not be an integral part of the package. It further defines a subcategory as follows: Heat Reclaim Water-Chilling Package is a factory-made package, designed for the purpose of chilling water and containing a Condenser for reclaiming heat. Where such equipment is provided in more than one assembly, the separate assemblies are to be designed to be used together, and the requirements of rating outlined in this standard are based upon the use of matched assemblies. It is a package specifically designed to make use of the refrigerant cycle to remove heat from the refrigerant and to reject the heat to another fluid (air or water) for heating use. Any excess heat may be rejected to another medium, usually air or water. US AHRI The ANSI/AHRI 560:2000 standard for rating absorption water chilling and water heating packages defines absorption chillers as follows: Absorption Water Chilling and Water Heating Package Is a factory designed and prefabricated assembly employing water as the refrigerant and consisting of an evaporator, absorber, condenser, generator(s) and solution heat exchangers, with interconnections and accessories used for chilling or heating water. The package Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 41

42 utilizes single or multiple reconcentrations of an absorbent solution. The reconcentrations of the absorbent are known as effects. A single effect package employs one step reconcentration of the absorbent in the generator. Water vapour is released after the heat energy is introduced into the generator. The concentrated absorbent is returned to the absorber where its double effect package employs a two step reconcentration of the absorbent through the use of an additional high temperature generator. An absorption package can be further defined by the following: Product description Direct Fired Package. This type of package reconcentrates the absorbent from heat energy through the combustion of natural gas, LP gas or oil. Indirect Fired Package. This type of package reconcentrates the absorbent from heat energy from steam or hot water. Chillers can be used both in industrial applications for refrigeration purposes and in buildings for air-conditioning purposes. They comprise a refrigeration system and are connected to a water (or water/glycol mix) circuit driven by a pump. Chillers can be found either as packaged factory assembled units or can be field erected assembly with different components. Both vapour-compression and absorption refrigeration cycles are used. This can be explained by the fact that in buildings or industrial processes, heat losses can occur which can be used to drive the absorption based chillers, leading to significant electricity savings compared to the use of a vapour-compression based chiller. Chillers operation temperatures range from -25 C to +15 C, with 3 subclassifications retaken by EUROVENT Certification program and discussed with stakeholders: high temperature chillers: leaving chilled water temperature between +2 C and +15 C; medium temperature chillers: leaving brine temperature between -12 C and +3 C; and low temperature chillers: leaving brine temperature between -25 C and - 8 C. High temperature chillers are predominantly used for comfort cooling, and are hence excluded from the scope of the study, while medium and low temperature chillers are used for industrial process refrigeration applications and are investigated. High operation temperature equipment will be considered under the scope of ENTR Lot 6. In order to reach low and medium temperatures, the water used in the chiller is mixed with Ethylene glycol or propylene glycol. The efficiency of the equipment will decrease with the increase of the concentration of this substance. Another factor affecting the efficiency corresponds to the differential of temperature. The choice of the type of technology depends mostly on the application range, as described in Table Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

43 Table 1-11: Technologies applied in chillers according to capacity range 49 Cycle Vapour Compression Technology Centrifugal compressor Screw compressor Scroll compressor Absorption Reciprocating compressor 1 Relevant for air conditioning 2 Relevant for refrigeration, air-cooled 3 Relevant for refrigeration, water-cooled -: Non-available data Process chillers Typical Capacity Range (kw) (and tonne of refrigeration) 1 >200 (60) 200-1,500 (50-400) < 750 (215) (20 150) > 15 (5) Typical Capacity Range (kw) (and tonne of refrigeration) ,900 (30 540) (3 70) Typical Capacity Range (kw) (and tonne of refrigeration) ,000 (85 2,600) 100 1,900 (30 540) (4 50) Non-applicable Non-applicable Process chillers for refrigeration are used in many different applications 50 to provide cold water and process refrigeration and can be either plug-in appliances (packaged) or uniquely designed to meet customers specifications. A single chiller cannot fit every temperature level requirement. Some chillers are designed to cool to very low temperatures while others are designed for only midrange applications. Some designs can support very high flow rates of fluid and others are designed for low rates of fluid. The same issues apply with ambient temperatures. Some chillers use refrigerant suited for a high ambient temperature environment while other refrigerants are formulated for cooler conditions. Packaged chillers are factory-assembled refrigeration units that are designed to cool liquid using a plug-in, electrically-driven mechanical vapour-compression system or gas fired absorption system. Packaged chillers based on vapour compression systems include the refrigeration compressor(s), controls (e.g. temperature settings, etc.) and the evaporator in the packaged unit. The condenser may also be integrated or remote, air-cooled or water-cooled (see Figure 1-10). Some packaged chillers may also include a unit comprising a chilled water (or water/glycol mix) buffer tank and a chilled water (or water/glycol mix) circulation pump which constitutes the coolant circuit hardware (see Figure 1-11). 49 Alliance for Responsible Atmospheric Policy, Global Comparative Analysis of HFC and Alternative Technologies for Refrigeration, Air Conditioning, Foam, Solvent, Aerosol Propellant, and Fire Protection Applications, Final Report, March 21, E.g. Plastics & Rubber: presses, injection, moulding, extrusion, blow moulding, thermoforming, PET; Lasers: cutting, welding, profiling, optics, medical, engraving; Food & Beverage: confectionary, bakeries, distilleries, breweries, wineries, dairies, bottling, carbonation, meat and fish, processing, vegetable and salad processing, storage; Chemical & Pharmaceutical: jacketed, vessels, polyurethane foam mixers, natural gas, industrial cleaning, laboratories, healthcare, solvents, paints, photo processing, oil cooling; Metal Working: processing and transformation of precious metals, aluminium working and processing; Mechanical & Engineering: machine tools, welding machines, rolling mills, presses, extruders, cutting, profiling, polishing, electric spark machinery, hydraulic control unit oil, oiling, pneumatic transport, heat treatment; Paper & Related Applications: printers, cardboard, labels, plastic film and other applications Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 43

44 Packaged chillers without these two components of the coolant circuit integrated are also known as split chillers (see Figure 1-10). These units deliver a cooling capacity ranging from 1.75kW to 700kW in the case of packaged chillers with air-cooled condensers, and up to 7,050 kw in the case of packaged chillers using a water-cooled condenser. Figure 1-10: Existing configurations for packaged chillers 51 Figure 1-11: Packaged chiller integrating the coolant circuit pump and tank 52 Packaged absorption based chillers also exist which are driven by gas combustion. Such products include a gas burner which serves as the heat source to drive the generator. 51 UK Carbon Trust, Industrial refrigeration equipment, A guide to equipment eligible for Enhanced Capital Allowances Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

45 Figure 1-12: Packaged absorption chiller (packaged) and its refrigeration cycle 53 Larger compression chillers are referred to as packaged chiller plants and are factory-assembled units but without any casing. These larger chillers can rely on compression or absorption technologies and can provide cooling capacities up to thousands of kw. These larger central plants can incorporate a pump and tank or not. Some manufacturers also propose customised solutions. Such chillers are bespoke projects assembled in-situ with component parts from various sources to match the design specifications. It is assumed that the average typical electricity consumption for industrial process chillers amounts to around 400,000 kwh/year Source : ROBUR 54 MTP, What If tool, data updated April Available at:whatif.mtprog.com/level3/productdetail.aspx?scenarioid=0&comparison=false&year=2008&s chemeid=1&productid=51 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 45

46 Chillers used in air-conditioning processes Chillers used in air conditioning processes are the core of a larger system which comprises air-handling units, with a network of pipes and pumps to connect them (see Figure 1-13). Figure 1-13: Typical water cooled chiller system 55 Such chillers can either rely on the vapour-compression (Figure 1-14) cycle or the absorption-cycle (Figure 1-15). Figure 1-14: Typical water cooled chiller using compression technology Source: US Energy Star 56 TRANE. Operation Maintenance Manual CVGF-SVU02B-E4. 46 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

47 Figure 1-15: Typical water cooled chiller using absorption technology 57 The variation of the efficiency according to the outlet temperature for an equipment of the same capacity is shown in Table The factor of variation was provided by stakeholders and is only an approximation, as the same equipment is not likely able to perform at extremely different temperature ranges. Table 1-12: Change of the efficiency according to outlet temperature for equipment of the same capacity, considering high temperature equipment as base Outlet temperature range Average outlet temperature Efficiency factor ( C) ( C) +2 / X -12 / X -25/ X Functional unit and performance parameter The primary function of a chiller is to cool down and maintain the temperature of a liquid (e.g. water, water/glycol mix) to cool an environment, process or product to an appropriate level of temperature. The functional unit is therefore the cooling capacity, in kw, considering a reference ambient temperature at which the measurement is done (+30 C for water-cooled equipment and +35 C for aircooled equipment) The performance parameter of chillers is expressed using the COP 58, which is the ratio between the cooling capacity and the power input. The heating performance of chillers is also expressed using the COP which is the ratio of the heating capacity (i.e. heat given off from the refrigerant to the liquid being heated per unit of time in reverse cycle operation) to the power input of the unit. Chillers usually operate at full load only during a limited period of time during a year. Therefore, the part load performance is much closer to reality. In the US, the performance of chillers is expressed as the Integrated Part Load Value (IPLV) which 57 TRANE. Trane horizon Absorption Series. ABS-PRC0016EN 58 COP: Coefficient of Performance: ratio between cooling capacity and power input Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 47

48 is the average power input based upon a chiller operating at part loads through a cooling season. In the EU, an index called ESEER Seasonal energy efficiency ratio is used. This index is similar to IPLV and takes into account several parameters in order to establish an average use of chillers throughout EU: weather data, building load characteristics, operational hours etc. Stakeholders commented that this ratio was soon to be replaced by the SEER, as mentioned in pren 14825: Chiller classification and scope for the study Chillers represent a very wide range of products, not only in terms of applications but also technologies. AHRI 550/590:2003 proposes a classification to water chillers depending on the cooling medium (Water-cooled chillers, evaporatively-cooled and air-cooled), while ANSI/AHRI 560 proposes a classification for absorption chillers based on the technology (single stage indirect fired, two-stage indirect fired and two-stage direct fired) EUROVENT certification program presents classification of equipments depending on the following parameters: heat rejection: water cooled or air cooled; system: packaged, split or remote condenser; operation type: cooling only or cooling/heating; duct: ducted or non-ducted; compressor type (centrifugal, screw, etc.) The UK ECA scheme classifies packaged chillers according to their capacity related to the technology implemented in the system. However, it only includes within the scope vapour-compression units. It considers the following four groups 59 : air-cooled packaged chillers that only provide cooling and have a cooling capacity that is less than or equal to 1,500kW; air-cooled, reverse cycle, packaged chillers that provide heating and cooling and have a cooling capacity that is less than or equal to 750kW; water-cooled packaged chillers that only provide cooling and have a cooling capacity that is less than or equal to 2,000kW; and water-cooled, reverse cycle, packaged chillers that provide heating and cooling and have a cooling capacity that is less than or equal to 2,000kW. The sub-classifications for the cooling capacity, related to EER and COP are shown in Table ECA Energy Technology Criteria List 2009 Refrigeration Equipment. Packaged Chillers 48 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

49 Table 1-13: UK ECA packaged chillers classification by technology and cooling capacity Product Category Cooling Capacity CC (kw) Without integral free Air-cooled packaged chillers that cooling mechanisms < 1,500 provide cooling only With integral free cooling mechanisms < 1,500 Air-cooled, reverse cycle, packaged chillers that provide heating and cooling < 750 Water-cooled packaged chillers that provide cooling only < 2,000 Water-cooled, reverse cycle, packaged chillers that provide heating and cooling < 2,000 This classification corresponds to comments from stakeholders. For higher capacities, only water cooling is applicable. The classification from the industry is firstly related to the use phase (heating, airconditioning, applied systems and refrigeration) and the required capacity or size (Table ). Under the scope of this study, only refrigeration systems are taken into consideration. Table 1-14: Industry s common classification of chillers Size Capacity (kw) Small Medium Large Extra-large > 901 Industry disaggregates chillers according to the type of compressor used: rotary vane: mostly used for low capacities (<15kW) being air-cooled; scroll: used for medium capacities ( kw) being water-, air-cooled and condenser-less; screw: used to obtain medium high cooling capacities (150 2,000kW) being water-, air-cooled and condenser-less; manufactures claim to reach low temperature though the use of semi-hermetic screw compressors; centrifugal: equipment using this technology are able to reach high cooling capacities (300 9,000kW), being water-cooled; reciprocating: kw, being air-cooled. Classification by temperature range (-25 C/-8 C; -12 C/+3 C; +2 C/+15 C) is suitable for discriminating the final use of chillers. The lower and medium ranges are normally used for refrigeration and cold storage, while the highest range corresponds to comfort. Some industrial processes have output water chilled Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 49

50 between +4 C and +6 C these products might require specific performance constraints different from air-conditioning equipment. Some stakeholders stated that the power capacity and size are common classifications because they provide with the necessary information about energy and working capacity (even if they reach the same temperatures). The cooling system of each chiller is relevant as it will have environmental consequences. Also, it is very important to take into account the type of refrigerant for environmental reasons. However, the energy performance of the equipment is more related to the configuration than the type of refrigerant used 60. According to stakeholders, there is a size limitation for packaged chillers, having up to 5MW of cooling capacity if it is water-cooled, and up to 1,500-1,800kW if it is air-cooled (due to limitations regarding noise problems). Air cooled equipment is also less energy efficient than water cooled ones 61. Chillers Low temp Air-cooled 3 Capacity 1 Medium temp Water-cooled 4 High temp 2 1 Capacities considered 1 Capacities to be from to 15kW be from to 1000kW. 15kW to The 1000kW. compressor The compressor type will be type related will to be the related capacity to required the capacity 2 Low temperature: required -25 C / -8 C, Medium temperature: -12 C / 3 C, High temperature: 2 C / 15 C Not considered 2 under Low the temperature: scope of Lot 1, -25 C therefore / -8 C. absorption Medium temperature: chillers are not -12 C considered / +3 C. in High the preparatory temperature: study. +2 C / Equipments to be +15 C considered (not considered by Lot 6 under the scope of ENTR Lot 1, therefore absorption chillers are not considered 3 Relevant especially in the for scope small of capacity the study) equipments 4 Only relevant for 3 big Relevant capacity specially equipments for small capacity equipment 4 Only relevant for big capacity equipment Figure 1-16: Chiller classification The following table describes some of the main differentiating criteria related to the product group, which may impact energy consumption. 60 Mark Ellis consultation Energy Efficiency Ratio (EER) - a ratio of the cooling capacity in Btu/h to the power input values in watts at any given set of Rating Conditions expressed in Btu/(W h) 50 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

51 Table 1-15: Specifications of process chillers Categorisations Explanation Notes Configuration Field-erected or packaged Comments from stakeholders indicated that the configuration of the equipment does not significantly influence the energy consumption (as long as it is properly installed) Operation temperature Location of condensing unit Ambient temperature Cooling capacity High, medium or low Packaged equipment with integral condensing unit Remote, connected to a central plant or exterior condensing unit The ambient temperature can influence the choice of the refrigerant, as well as the performance The compressor and system used depends on the operating temperature and the cooling capacity of the product. The efficiency of chillers decrease for lower temperatures. Influences ambient temperature - climate zones (air-on temperature) northern/southern EU relevant for remote Two main climate zones could be distinguished in the EU-27: around +11 C for northern Europe and around +15 C for southern Europe For low cooling capacities, the most used compressor is hermetic reciprocating; while for medium and high cooling capacities the compressor can be semi-hermetic reciprocating, scroll or screw. Large cooling capacities require compressor packs and racks Refrigeration system Vapour compression or absorption - There are different technologies applicable to compressors: reciprocating (hermetic and semihermetic); Compressor type - scroll ; rotary ; and screw Condenser type Water, air, evaporative - Refrigerant The choice of refrigerant depends on the operation temperature, ambient - temperature, refrigeration system type Anti-freezing agent Additive to avoid water freezing at lower temperatures. Ethylene glycol, propylene glycol and brine are typically used from 10% to 40% depending on the target temperature. - Chillers covered in the study are those that operate at low and medium temperature (see ) those that are predominantly used for commercial and industrial freezing or chilling and chillers used for high temperature applications are excluded (to be covered by ENTR Lot 6). Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 51

52 REMOTE CONDENSING UNITS General product definition Remote condensing units are a classification of products which only comprise of part of the refrigeration cycle: the compressor and the condenser. The evaporator and expansion valve are components which, as supplied, are integrated in the cold storage devices (cabinets, cold rooms, etc.) and are required to complete the system. There are typically three fundamental system arrangements: packaged condensing units (PCUs) with one or more compressors; non-packaged condensing units with independent compressor and condenser; compressor packs or racks independent from the condenser. PCUs are products which include one or more compressor(s) and condensing equipment for cooling rooms or large spaces, such as cool storage rooms, or for providing refrigeration service to other locations. Remote refrigerating appliances (i.e. not plug-in appliances), including the products discussed above, can be connected to the PCU. PCUs are commonly installed in walk-in cold rooms in clubs, pubs, hotels, butchers and other food preparation and service industries. They are also widely used in supermarkets. In most of these places, additional refrigeration energy is provided by self-contained central refrigeration units, however the large majority of refrigeration energy is provided by PCUs 62. Non-packaged condensing units are independent compressors and condensers that can be sold and installed separately and thus can be considered as a customised cooling system. Compressor packs are framed packages of up to ten compressors, the average is three, with one or more remote condensers designed for commercial refrigeration purposes. When compressor packs are used for industrial processes, they are designed as compressor racks. These appliances are designed to be incorporated into a refrigeration system and normally mounted indoors in mechanical rooms, for large applications such as supermarkets. They require an external condensing unit (or less commonly can have integrated water cooled condensers). A compressor pack or rack is defined as an assembly of one or more compressors complete with interconnecting pipe work. They may include liquid receivers, filter driers, oil separators, shut-off valves and related controls, and are supplied on a structurally rigid frame. Most packs are in the range 30 kw to 400 kw, reaching a maximum of 900 kw. They are generally customised, adjusted and installed according to the needs of the customer. A typical compressor pack (commercial cooling) or rack (industrial cooling) is factory assembled and incorporates at least the following components: 62 Analysis of Potential for Minimum Energy Performance Standards for Remote Commercial Refrigeration, Mark Ellis & Associates, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

53 one or more electrically driven refrigeration compressors; and a control system that controls the product s compressor(s) and cooling fan(s). Non-packaged condensing units and compressor packs/racks, which operate independently from the condenser, are not complete condensing units because they do not have condensers integrated, but only compressors and controls. These two parts are sold independently, and thus the performance is measured only on the compressor or on the condenser fan motors. When the compressor is sold as an independent product it is affected by the regulation EC 640/2009 for electric motors. For this reason, non packaged condensing units and compressor packs/racks are not under the scope of this preparatory study and will not be further investigated Existing product definitions A condensing unit is defined as an assembly of a condenser and one or more compressors completed with interconnecting pipe work. They may include liquid receivers, filter driers, oil separators, shut-off valves and related controls, as well as a weatherproof housing 63. PCUs cover products that are specifically designed to provide cooling to other equipment that incorporate evaporators (and associated expansion valve control systems). According to the International Dictionary of Refrigeration 64, a condensing unit is an assembly including a compressor with motor, a condenser, and a liquid receiver when required. In the EN 13215:2000 standard, condensing unit is defined as combination of one or more compressors, condensers or liquid receivers (when applicable) and the regularly furnished accessories. In the EN :2007 standard, a condensing unit is defined as a factory assembled unit comprised of refrigeration compressor and motor, condenser and any necessary associated ancillaries. In the UK ECA Scheme certification programme, air cooled condensing units are defined as factory-assembled units that consist of an air-cooled condenser, one or more compressors, and interconnecting pipe work. They may include liquid receivers, filter driers, oil separators, shut off valves and related controls, and a weatherproof housing Product description PCUs are factory-assembled, packaged units that consist of a refrigeration compressor, a motor, a condenser, and various others components. This packaged unit does not contain a complete refrigeration system, but is designed to provide a cooling for a cold room or other equipment fitted with an evaporator that is controlled by an expansion valve. 63 ECA Energy Technology Criteria List Technology: Refrigeration Equipment, August International Institute of Refrigeration. International Dictionary of Refrigeration Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 53

54 A typical PCU is factory assembled and incorporates at least the following components: refrigerant condenser; one or more electrically driven refrigeration compressors; and a control system that controls the product s compressor(s) and cooling fan(s). PCUs are placed on the market as a complete product. Configuration of the system (such as the piping system between the condensing unit and the remote appliance(s)) may be dealt with by the installer or the user. Figure 1-17: Typical packaged condensing units - individual compressor unit and parallel compressor unit. PCUs are used in a variety of commercial and industrial cooling applications, including cold rooms, refrigerated display cabinets, back-bar equipment, temperature controlled food preparation areas, and for air conditioning systems. The average remote condensing unit is based on the Standard Specifications 65. Two main types of PCUs were identified: 3-20 kw (air cooled); and kw (air cooled). However, this classification of capacity ranges does not match the classification split used in the industry, because most of the condensing units are between 3-50 kw and capacities higher than 100 kw are only used for large systems. Thus, the classification proposed by this preparatory study follows the recommendations made by stakeholders. The most commonly used RCUs are air cooled and consist of an hermetic reciprocating compressor, air-cooled condenser coil, fan, motors, refrigerant reservoir, and operating controls. These figures will be further explained in the market data section. According to the answers received to the 1 st ENTR Lot 1 questionnaire 66, it is assumed that the average RCU equipment (a condensing unit using a single reciprocating compressor with on/off motor, running R404A as refrigerant liquid and with 5 to 7 kw of cooling capacity measured at +32 C ambient temperature 65 Specification Standards from University of Washington 66 BIO Intelligence Service. First ENTR Lot 1 online questionnaire to stakeholders. Different versions of the questionnaire are available depending on the product category and can be downloaded from 54 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

55 and +10 C evaporating temperature, with a condenser fan of 130W) consumes around 20,000 kwh/year. This estimation varies depending on the ambient temperature, evaporating temperature, refrigerant used, type of compressor and fan, characteristics of the system and workload, leakage rate, etc Functional unit and performance parameter The function of remote refrigeration systems is to provide refrigeration service to other appliances. Therefore the way of calculating the electricity consumption of the remote condensing units is using the REC, in kilowatt hours per 24-hour period. This refers to the electricity consumption of the condenser and the compressor which is used to provide cooling energy to the appliance. REC is based on the input and output temperatures of the liquid refrigerant circulating in and out of the remote product. The remote condensing units work an average of hours per day, 365 days per year. These working hours are not continuous, and the length of each working time depends on the needs of the system. The rest of the time the condensing unit does not consume energy, according to information received from stakeholders. The ambient temperature varies for the different countries in the EU, from an average of +11 C in northern member states to +15 C in the southern member states. However, the ambient temperature stated in the testing standard EN 13215:2000 is +32 C. The functional unit identified for these equipments is kw of cooling capacity. The proposed performance parameter is the coefficient of performance (COP 58 ) Remote condensing units classification and scope for the study A classification for RCUs included in the scope of the study is illustrated below in Figure This classification was developed with the industry and considers the parameters typically used. Categorisation of appliances begins with the layout of the refrigeration components. Packaged condensing units with integrated compressors which are intended to be mounted outside are one category, the next category being packaged condensing units with multiple compressors. Compressor packs requiring externally mounted condensers and independent compressors and condensers do not fit the existing definitions of condensing units and are left out of the scope of this study, as explained above. The packaged condensing units can then be subcategorized by the evaporating temperature which determines the capacity, size of compressor, energy consumption, etc. Finally the capacity of the unit can help to classify the product. Other characteristics to further classify remote condensing units are compressor type (reciprocating, scroll, screw or rotary), compressor motor speed drive (on/off, two speeds, variable speed) and condenser cooling (air or water cooled). Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 55

56 High capacity 2 Medium capacity Low temp. 1 Low capacity Packaged with single compressor Medium temp. as above Remote condensing units Packaged with multiple compressors High temp. as above out of scope Non packaged with independent condenser and compressor Independent compressor packs out of scope 1 High temperature: +5 C; Medium temperature: -10 C; Low temperature: -35 C 2 High capacity: > 50kW; Medium capacity: 20kW-50kW; Low capacity: 0.2kW-20kW Figure 1-18: Remote condensing unit classification Condensing units for high evaporating temperature (+5 C) are used in air conditioning systems whereas, in commercial refrigeration, only medium (-10 C) and low (-35 C) temperatures are used. As the scope of this preparatory study is commercial refrigeration, and air conditioning products are covered in ENER Lot 6 preparatory study (air conditioning and ventilations systems), condensing units for high temperatures are left out of the scope of the present preparatory study and will not be further investigated. However, some of the appliances designed for medium temperature can work at high temperature and vice-versa. The aim of this preparatory study is to inform the later discussion and consultation process which may lead to regulation the performance of the remote condensing units working on commercial refrigeration temperatures, even though the products affected can be used for other purposes. The share of the market that this kind of appliance represents is not taken into account in the various calculations. The following table describes some of the main differentiating criteria related to the product group, which may impact energy consumption. 56 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

57 Table 1-16: Specifications of condensing units Categorisations Explanation Notes Configuration Evaporating temperature Cooling capacity Compressor type Compressor motor drive Condenser type Refrigerant Ambient temperature The condensing units can be designed and sold as: packaged with single compressor(compressor and condenser on the same plate); packaged with twin compressors or more compressor packs or racks independent compressor and condenser Evaporating temperatures in food conservation applications are driven by legislation: frozen foodstuff must be under -18 C (LT). Low evaporation temp.: -35 C Medium evaporation temperature: -10 C High evaporation temp.: +5 C The compressor and system used depends on the operating temperature and the cooling capacity of the product. There are different technologies applicable to compressors: reciprocating (hermetic and semi-hermetic) scroll screw rotary The compressor motor can be driven with different technologies: on/off 2-speed variable speed drive Water cooled, air cooled. The choice of refrigerant depends on the operation temperature, ambient temperature, refrigeration system type. The ambient temperature can influence the choice of the refrigerant, as well as the performance of the condensing unit. Packaged and independent configurations can be sold as independent products by the industry Both packaged units and independent systems can use up to 10 compressors in order to obtain higher cooling capacities and efficiencies. The operating temperature determines the appropriate refrigerant and required cooling capacity. For low cooling capacities, the most used compressor is hermetic reciprocating; while for medium and high cooling capacities the compressor can be semi-hermetic reciprocating or scroll. Screw compressors are used in larger cooling capacities and mostly for air conditioning. Extra large cooling capacities require compressor racks. The most used compressor is reciprocating hermetic In partial load conditions, 2 speed and variable speed drive can achieve higher efficiencies than on/off compressors, but under full load conditions the on/off technology is more efficient. Stakeholder feedback has determined that most of the market is air cooled. The most commonly used refrigerant is R404a. Two main climate zones can be distinguished in the EU-27: around +11 C for northern Europe and around +15 C for southern Europe EN 13215:2000 standard establishes +32 C as standard temperature for testing; UK ECA Scheme establishes MEPS for +20 C ambient temperature. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 57

58 Categorisations Explanation Notes Location The location of the condensing unit can impact its performance. Should be placed in a well ventilated area, away from direct sunlight. Only packaged condensing units are included in the scope of the present study. The manner in which these products interact with the system they operate under is very important for the overall efficiency of the system and therefore must be analysed from an ecodesign perspective PRODCOM DEFINITIONS In order to better identify the types of equipment that can be considered as refrigeration and freezing equipment, existing product classifications used by PRODCOM 67 are identified. PRODCOM classifies commercial refrigerators and freezers in the category NACE Manufacture of non-domestic cooling and ventilation equipment. In its subcategories different types of refrigerating appliances are listed, which are presented in Table Table 1-17: PRODCOM classification of commercial refrigeration equipment PRODCOM code PRODCOM category Refrigerating and freezing equipment and heat pumps, except household type equipment Refrigerated show-cases and counters incorporating a refrigerating unit or evaporator for frozen food storage Refrigerated show-cases and counters incorporating a refrigerating unit or evaporator (except for frozen food storage) Deep-freezing refrigerating furniture (except for chest freezers of a capacity 800 litres, upright freezers of a capacity 900 litres) Refrigerating furniture (except for deep-freezing, show-cases and counters incorporating a refrigerating unit or evaporator) Compression type units whose condensers are heat exchangers, heat pumps Absorption heat pumps Other refrigerating or freezing equipment It can be observed that commercial refrigeration appliances appear in this classification explicitly. However, apart from the capacity and the temperature, few criteria are used to distinguish between different types of products (e.g. no differentiation between plug-in and remote appliances). As some of the equipment of the commercial refrigeration sector is technically similar to domestic refrigeration equipment (e.g. service cabinets), the table below provides PRODCOM references for household-type refrigerators and freezers. 67 PRODCOM Classification: List of Products of the European Union 58 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

59 Table 1-18: PRODCOM classification of household refrigeration equipment PRODCOM code PRODCOM category Refrigerators and freezers, of the household type Combined refrigerators and freezers, with separate external doors Household type refrigerators (including compression-type, electrical absorption type, excluding built-in) Compression-type, built-in Chest freezers of capacity 800 litres Upright freezers of a capacity 900 litres Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 59

60 1.3. PRODUCT TEST STANDARDS, THEIR DEVELOPMENT AND OTHER STANDARDS The aims of this section are to give an overview of existing product standards, standards under development and associated test methods, to identify gaps, and to highlight needs for forums to discuss development of standards and creation of new standards. Please also see annex 1-2 for other standards related to the product groups. A testing standard is a standard that sets out a test method but does not indicate what result is required when performing that test. Therefore, strictly speaking, a testing standard is different from a technical standard. In technical use, a standard is a concrete example of an item or a specification against which all others may be measured or tested. Often it indicates a required performance level to be achieved in order to comply with the standard. Testing standards are also (but not exclusively) defined in the technical standard itself. For example, an ISO standard for a product or process gives detailed technical specifications, which are required in order to conform to that standard. It also defines testing methods to be followed for validating such conformity. A standard can be either product- or sector-specific, and it can concern various stages of a product s life cycle. The main focus in this subtask is on environmental performance and related technical aspects (e.g. energy consumption and resource consumption) in relation to functional performance. However, for the sake of completeness, other standards (such as health and safety-related standards) related to refrigeration equipment are also considered. Test methods and standards exist for nearly all components used within refrigeration equipment and are presented in Annex 1-1. It is important to note that for product performance testing, different testing methodologies can lead to significant variations in test results for the same product, and that frequently for refrigeration there are requirements concerning limits to temperature fluctuations within the refrigerated space that relate to food safety. Therefore, although some standard performance parameter figures quoted in the literature may seem comparatively low, it is not always stated what standard methodology these figures have been measured under, and whether the product satisfies the food safety requirements SERVICE CABINETS Historically EN 441 has been the standard methodology for testing of service cabinets. It has been proposed that a new standard be developed for professional service cabinets in the EU, based on EN ISO 23953, and this process is being driven by EFCEM 68. This development has been slightly confused due to the different technical committees that are responsible for safety and performance of these products. TC59/61/E-C is relevant to safety, whereas TC59X is relevant to performance. Stakeholders estimated that the variation in results of performance testing can be 5 to 10% between EN 441 and EN ISO when evaluating the 68 Source: EFCEM, ENTR Lot 1 3 rd stakeholder meeting 60 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

61 same product 69. The differences between these two test methodologies are described in more detail in and EN ISO 23953:2005 (under revision) Relevance: Service cabinets, possible adaptability for blast cabinets EN ISO 23953:2005 Refrigerated display cabinets Vocabulary, Classification, requirements and test conditions (replacing former EN 441:1995) is used for energy consumption measurement of commercial refrigerated display cabinets for the sale and/or display of food products. In principle this standard can be used for measuring the energy performance of service cabinets as well. Scope: This standard does not cover service cabinets intended for use in catering or similar non-retail appliances, minibars, ice-makers, ice cream machines, milkshake machines and cold rooms. However, this standard could be used for performance calculation of professional service cabinets (for example, former version EN 441:1995 is used as a reference testing method in the framework of the UK ECA for commercial service cabinets). EFCEM and CECED Italia, in partnership with European manufacturers, are currently adapting EN ISO 23953:2005 for testing of professional service cabinets. The main changes are in the procedure used to evaluate the units, as the door openings required in the current version for commercial cabinets are considered as not representative of the typical use pattern for professional service cabinets. Recommended alterations include the following aspects. For calculation of net volume, where n is the number of shelves: Shelf or drawer base area x (loading height n x thickness of shelf). Please see for further discussion on measurement of internal storage volume. Test packages 70 have to follow air circulation direction. For temperature monitoring: as described in the picture below ( Figure 1-19), this should be carried out with one probe on the left, one in the centre and one on the right. Changes to the timings of door/lid openings. Please see for further discussion on these aspects of the test protocol. 69 Source: ARNEG 70 Manufactured gel (cellulose) with specific constrains to test service cabinets according to different standards. In some cases, thermocouple temperature sensors can be inserted into this device Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 61

62 Figure 1-19: Packages arrangement during temperature monitoring. One issue to note concerns the terminology used in EN ISO ENTR Lot 1 uses the term horizontal to define the orientation of the product. However, within EN ISO 23953, horizontal is a term used to describe the display area orientation (Part 1, Annex A). This potentially confusing terminology should be revised or clarified. Existing specifications The operating characteristics of equipment for testing are defined in the M- package 71 temperature classes and test room climate classes, described below. Class Table 1-19: M-package temperature classes Highest temperature of the warmest M- package less than or equal to Lowest temperature of the coldest M- package greater than or equal to Lowest temperature of warmest M- package less than or equal to C L L L M M H H S Special classification Test room climate class Table 1-20: Test room climate classes 72 Dry bulb temperature ( C) Relative humidity (%) Dew point ( C) Water vapour mass in dry air (g/kg) M-packages are test packages fitted with a temperature measuring device 72 Please see EN ISO Annex C for further details on the comparison of laboratory and real (instore) conditions 62 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

63 Test room climate class Dry bulb temperature ( C) Relative humidity (%) Dew point ( C) Water vapour mass in dry air (g/kg) The water vapour mass in dry air is one of the main points influencing the performance and the energy consumption of the cabinets. In addition to these product and test parameters, the standard defines requirements for factors such as thermal and air flow characteristics in the test room. Requirements: In order to calculate the energy consumption, EN ISO differentiates between plug-in cabinets and remote units. In general, this parameter is given by the TEC in kwh per 24-hour period. For the case of remote cabinets, the TEC indicator is the sum of the following: DEC calculation: REC calculation: DEC in kwh per 24hour period REC in kwh per 24-hour period, for remote cabinets DEC [(P V.t V ) (P H.t H ) (P D.t D ) (P L.t (Tc -T0) REC t R 0 (0.34 T ) TEC calculation: TEC DEC REC [kwh/24h] 0 L ) (P This scope of calculation is very similar to the one in ANSI/AHRI 1200 for the equivalent parameter Calculated Daily Energy Consumption (CDEC) (see ) in both cases the consumption from the condenser is not included in the consumption of the unit and is calculated separately. A.t A )] Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 63

64 Box 1-1: Definitions and unit of the measured parameters for EN ISO standard P V,H,D,L,A respectively fan, heaters, defrost heaters, lighting and accessories power (W) t V,H,D,L,A respectively fan, heaters, defrost heaters, lighting and accessories running time within 24h t R 24h minus defrost period in h T C conventional condensing temperature T 0 refrigerant evaporating temperature (based on test with 24h lighting) Φ 0 heat extraction rate in kw (based on test with 24h lighting) The heat extraction rate Φ 0 is defined by: Qtot 0 t R Q represents the total heat extraction in kwh n tot nnmax Q t tot represents the instant heat extraction rate in kwh. It is defined as: n N max t q m n1 ( h ) n q m 8 h (See Figure 1-20) 4 indicates the measuring sample. is the number of measuring samples in 24 hours is the time between two measuring sample is the mass flow rate of refrigerant in kg/s h, is the specific enthalpy in kj/kg at point 8 corresponding to the 8 4 refrigerant outlet and point 4 corresponding to the refrigerant inlet. EN ISO also deals with plug-in units. In this case, the TEC equals the DEC. The TEC includes the compressor energy consumption. For this kind of cabinet, the REC is not defined. This scope is similar to Total Daily Energy Consumption (TDEC) for ANSI/AHRI (see ). n 64 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

65 pressure P1 condensation expansion compression P2 evaporation enthalpy h 8 h 4 Figure 1-20: Example of a refrigeration system vapour-compression pressureenthalpy (P-s) diagram showing process stages related to the saturation curve EN 441 (UK and DK) Relevance: Service cabinets Refrigerated display cabinets. General mechanical and physical requirements was superseded by EN ISO It was composed of several parts providing terms, definitions, mechanical and physical requirements, dimensions, general tests, a temperature test, a classification according to temperature, a defrosting test, a water vapour condensation test, electrical energy consumption, a test for absence of odour and taste, an installation and user s guide, and measurement of the heat extraction rate of the cabinets when the condensing unit is remote from the cabinet. Although this standard has been withdrawn, it is still in use DE DIN (draft standards in progress) Part 1: Refrigerators and refrigerated counters (draft standard in progress) Part 2: Cooling trays (draft standard in progress) Part 4: Refrigerators and freezers, Requirements and testing Relevance: Service cabinets This standard contains requirements for design and function of refrigerators and refrigerated counters for food distribution, including testing, technical safety and hygiene features. However, no testing requirements are specified for service cabinets. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 65

66 ANSI/AHRI (US) Relevance: Service cabinets The ANSI/AHRI standard (superseding ANSI/ARI Standard ) Performance Rating of Commercial Refrigerated Display Merchandisers and Storage Cabinets describes a method for assessing the performance rating of commercial refrigerated display merchandisers and storage cabinets. This standard is voluntary. AHRI presented a certification related to this standard in 2008 which includes both remote and self-contained equipments. Scope: This standard applies to the following commercial refrigerated display merchandisers and storage cabinets, provided that the cases are equipped and designed to work with electrically driven, direct expansion type systems: plug-in and remote commercial refrigerated display merchandisers (already covered in the TREN Lot 12), plug-in and remote commercial refrigerated storage cabinets (ENTR Lot 1), open and closed commercial refrigerated display merchandisers (already covered in the TREN Lot 12). The standard excludes: commercial refrigerated display merchandisers forming the front wall of a refrigerated storage room backed up to a walk-in cooler wedge cases (Miter transition display merchandisers) used as a corner section between two refrigerated display merchandisers floral merchandisers refrigerated vending machines ice makers ice cream dipping cabinets soft serve extruders secondary coolant applications Test requirements: The tests required for this standard should be conducted in accordance with ANSI/ASHRAE Standard 72 (see ASHRAE standards). Definitions: Box 1-2 provides the definitions of the different parameters used in the ANSI/AHRI 1200 standard. 66 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

67 Box 1-2: Definitions and unit of the measured parameters for ANSI/AHRI 1200 standard (SI units included in square brackets) A e = Projected area from visible product through end walls, ft 2 [m 2 ] A r = Gross refrigerated area, ft 2 [m 2 ] AEC = CDEC = CEC = COP = DEC = D h = E t = EER = FEC = IU = LEC = LECR = L = n = P ai = P c = P d = P f = P fi = P fo = P li = PEC = Qrt = t = ta = tc = td = tdt = tf = tl = TDA = TDEC = Anti-condensate energy consumption, kw h[kw h] per day Calculated Daily Energy Consumption, kw h [kw h] per day Compressor Energy Consumption, kw h [kw h] per day Coefficient of Performance Defrost Energy Consumption, kw h [kw h] per day Dimension of projected visible product, ft [m] Total energy measured or calculated for 24-hour period, kw h [kw h] per day Energy Efficiency Ratio Fan Energy Consumption, kw h [kw h] per day International Units Light Energy Consumption, kw h [kw h] per day Revised Light Energy Consumption, kw h [kw h] per day Length Length of Refrigerated Space, ft [m] Number of fan motors Power anti-condensate heater input, W [W] Power condensate evaporator pan heater input, W [W] Power defrost heater input, W [W] Power fan, W [W] Power fan input, W [W] Power fan output found on part nameplate, W [W] Power light input, W [W] Condensate Evaporator Pan Energy Consumption, kw h [kw h] per day Commercial refrigerated display merchandiser or storage cabinet load, Btu/h [W] Time unit is tested in 24 h period, h [h] Time anti-condensate heaters are on in 24-hour period, h [h] Time condensate evaporator pan heaters are on in 24-hour period, h [h] Time defrost heaters are on in 24-hour period, h [h] Time unit is in defrost, h [h] Time fans are on in 24-hour period, h [h] Time lights are on in 24-hour period, h [h] Total Display Area, ft² [m²]/unit of Length, ft [m] Total Daily Energy Consumption, kw h [kw h] per day Vr = Refrigerated Volume, ft 3 [m 3 ] ηm = Motor efficiency Rating requirements: Box 1-3 and Box 1-4 provide the details of the calculation of the CDEC 73 and of the TDEC 74. The performance rating for remote cabinets calculates the CDEC with an approach similar to what is done in the ISO 23953, i.e. EER and COP values used to calculate the energy consumption of the refrigeration system are conventional values for a typical reciprocating compressor which are provided in the standard (Table 1 of ANSI/AHRI 1200:2008). 73 CDEC is the value for remote commercial refrigerated service cabinets based upon the requirements of this standard expressed in kw h [kw h] per day. 74 TDEC Is the calculated energy consumption value for plug-in service cabinets based upon the requirements of this standard expressed in kw h [kw h] per day. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 67

68 Box 1-3: Performance rating for remote commercial refrigerated display merchandisers and storage cabinets CDEC calculation: CDEC=CEC+FEC+LEC+AEC+DEC+PEC Calculation of CEC CEC = [(Q rt ).(t-t dt )]/(EER.1000) CEC = [(Q rt ).(t-t dt )]/(COP.1000) Calculation of FEC FEC = (P f.t f )/(1000) P f = P fi (if measured) P f = (P fo.n)/η m (if calculated) Calculation of LEC LEC = (P li.t l )/(1000) Calculation of AEC AEC = (P ai.t a )/(1000) Calculation of DEC DEC = (P d.t d )/(1000) Calculation of PEC PEC = (P c.t c )/(1000) Other parameters calculation Refrigerated volume V r = A r.l (if IU) Total display area (display cabinets) TDA = (D h.l)+a e Presentation of the data 68 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

69 Box 1-4: Performance rating for self-contained commercial refrigerated display merchandisers and storage cabinets TDEC calculation: TDEC = E t /L Other parameters: Refrigerated volume V r = A r.l Total display area Presentation of the data TDA = (D h.l)+a e US ASHRAE Standard Relevance: Service cabinets ASHRAE Standard Method of Testing Commercial Refrigerators and Freezers (ANSI Approved) is the revision of Standard It combines standard for open refrigerators and standard for closed refrigerators. It prescribes a uniform method of testing both remote and selfcontained open and closed commercial refrigerators and freezers for rating so that comparative evaluations can be made of energy consumption, product temperature performance, refrigeration load, the suction pressures required and other performance factors. The standard also clarifies door opening requirements, shelf loading and test definitions, and includes requirements that improve the consistency of ambient temperatures CAN/CSA-C (R2008) Relevance: Service cabinet CAN/CSA-C (revised in 2008) Energy Performance Standard for Food Service Refrigerators and Freezers applies to commercial refrigerators, refrigeratorfreezer cabinets that are intended for storing and holding food products and other perishable merchandise. It applies to manufacturers standard catalogue-type equipment, closed cabinets of the unitary, self-contained type; and commercial refrigerated storage cabinets, regardless of their shape, size or configuration. It does not apply to remote-condensing commercial refrigerators and freezers, walkin refrigerators and freezers, water coolers, refrigerated vending machines, icemaking machines, soft serve, slush and shake-dispensing freezers and extruders. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 69

70 The CSA standard contains minimum performance criteria for annual energy consumption that vary with the volume of the refrigerator or freezer (see ) Comparison of volume measurement methods Stakeholders commented on their volume measurement methods. There are three that have been considered as the most important: Method 1: This method considers the internal vertical distance from the lowest usable shelf to the highest load-line multiplied by the usable shelf area when the door is closed. Method 2: This methodology considers the space within the equipment with all movable parts removed. It provides a gross volume, from which the space required for the evaporator and air ducts free flow should be deducted. Method 3 (corresponding to EN 441): This method measures the equipment with all movable parts installed. The load limits are identified, considering areas where the air channels that should not be blocked at any moment. Volume inferior to 100x100x100mm (cubic testing package) should not be included for the calculation. The measurement should fit primitive geometrical shapes. The volume of the bottom shelf shall not be included in the total volume. Method 4 (corresponding to EN revision proposal 75 ): Where n is the number of shelves: Shelf or drawer base area x (loading height n x thickness of shelf). Following are some of the issues associated with trying to develop a harmonised and accurate measurement method which reflects the amount of food that the product can store during use 76 : In some cabinets, the shelves are recessed and therefore would not actually have food on them. Many cabinets are quite poor in terms of load lines and dimensions and so any rule can be interpreted in a variety of ways (hence it would be useful to insist that load lines are marked). The number of test packs might be a good method, though loading is only approximately half the shelf height. Another stakeholder comment noted that the volume of the test packs used in determining the energy consumption should also be used in the energy/volume index calculation (there is an inherent inaccuracy when testing energy with one volume of product and then introducing another volume of product when calculating the energy efficiency index) 77. Care should be taken when selecting a method considering the trade-off between convenience and accuracy. 75 Source: CECED Italia 76 Source: London South Bank University 77 Source: Adande Refrigeration 70 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

71 Testing and protocols There are three main elements of testing for service cabinets, due to their significant impact on energy consumption: ambient temperature and humidity, M- package positioning, and door openings. Climate classes are used to define standard temperatures and humidity, and positioning of M-packages is defined within the standards. The term protocol is used to describe the assumed use pattern that is replicated by a specific door opening pattern during the controlled test. The standards EN ISO 23953, the development of this standard by CECED and the standard EN 441 all have slight protocol variations. These reflect differences in assumed use patterns, in order that the testing method accurately reflects real consumption. EN 441-5:1996 Cabinets with doors were tested over a 48-hour period where the cabinet door(s) were opened cyclically for 12 h within each 24-hour period. If the cabinet was fitted with lights these were switched on 1 h before the start of the door-opening test and were switched off 1 h after the door-opening period. Start 0-12 hours hours 3 min open each door opened 6 times per hour for 12 seconds (1) each door closed 24 hours 3 min open hours hours each door opened 6 times per hour for 12 seconds 1 each door closed 1 Door open at an angle of greater than 60 for 10 s. If the cabinet has multiple doors, the doors are opened in sequence within each 10-min period. EN ISO 23953:2005 The test for closed refrigerated cabinets should always be carried out on a complete cabinet, regardless of the number of doors or lids. The requirements state that the cabinet lighting should be switched on for a period of 12 h; followed by 12 h with the cabinet lighting switched off. With the night covers removed, leave the cabinet lighting switched on for a period of 12 h; followed by 12 h with the night covers on and the cabinet lighting switched off. Start 0-12 hours hours 3 min open (2) each door or lid opened 6 times per hour for 6 seconds (3) each door closed (2)Where a cabinet is provided with more than one door or lid, each door or lid shall be opened for 3 min consecutively. (3)Door open at an angle of greater than 60 for 4 s. If the cabinet has multiple doors, the doors are opened in sequence within each 10-min period where there are two doors, for example, open door no. 1 at 0 min, door no. 2 at 5 min, door no. 1 at 10 min, door no. 2 at 15 min, and so on. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 71

72 CECED Italia EN ISO 23953:2005 revision Procedure: during the 24 hours, consumption measurements should be recorded as follows. Freezing Start 0-4 hours 4 8 hours 8 hours 8 12 hours hours 1 min open each door opened 6 times per hour for 6 seconds (4) each door closed 1 min open each door opened 6 times per hour for 6 seconds (4) each door closed Refrigeration Start 0 12 hours hours 2 min open cycle each door opened 6 times per hour for 6 seconds (4) each door closed (4)Where more than one door or lid pertains to the cabinet to be tested, the sequence in which the doors and lids are opened shall be staggered. FR NF AC D40-003:2006 ( ) 1 st period 2 nd period 3 rd period 5 hours 3 hours 1 hour Door closed: cooling of M- packages to required temperatures Door openings For high temperature: The door is open to 90, every 5 min for 10 seconds. In the case of the product having several doors or drawers, they should be opened one at a time, every 5 minutes in turn. For low temperature: The door is open to 90 every 15 min for 30 seconds. In the case where the device has several doors or drawers, they should be open one at a time, every 15 min in turn. Door closed: cooling of M- packages to required temperatures Understanding of product use patterns is important when developing testing standards. A field study tested products using different door opening patterns, demonstrating the impact this can have on energy consumption. 72 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

73 Electricity consumption [kwh/24h] Electricity consumption [kwh/24h] Electricity consumption vs. dooropenings Old y = 0,079x + 8,0439 R 2 = 0, New y = 0,0347x + 3,9587 R 2 = 0, No. of dooropenings [1/24h] Figure 1-21: Electricity consumption vs. door openings for the freezers 78 Electricity consumption vs. Door openings Old 660 y = 0,0134x + 4,7319 R 2 = 0, New 660 y = 0,0049x + 1,0926 R 2 = 0, No. of door openings [1/24h] Figure 1-22: Electricity consumption vs. door openings for the refrigerators Pedersen, P-H., Soe, L. and Jensen, F. New Generation of Professional Kitchen Appliances with Natural Refrigerants and Reduced Energy Consumption, Danish Technological Institute and Gram Commercial. Presented at 6th Gustav Lorentzen Natural Working Fluids Conference, Glasgow, UK (2004) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 73

74 BLAST CABINETS EN 328: EN 327:2000 Relevance: Blast cabinets, heat exchangers Heat exchangers. Test procedures for establishing the performance of forced convection unit air coolers for refrigeration. This standard is applied to evaporators in direct dry expansion of refrigerant, liquid feed by means of a pump and machines working with liquids, and includes non-ducted unit air coolers for refrigeration operating. It is used to evaluate blast cabinet component performance, but not the overall performance of the equipment. It establishes performance evaluation methods. These methods determine the net power of the evaporator, air-flow, and energy consumption. This standard does not include safety aspects or evaluation of conformity. Relevance: Blast cabinets, packaged refrigeration systems Heat exchangers Forced convection air cooled refrigerant condensers Test procedure for establishing performance. This standard applies to remote condensers, air-forced convection condensers where refrigerant change phase is produced. This is standard is used to determine the functioning of blast cabinet components, but not of blast cabinets by themselves. This standard establishes performance evaluation. However, it does not provide compliance values, and does not apply to condensers meant to be installed inside machines or cabinets, or condensing units with subcooling units DE DIN 8953/8954 Relevance: Blast cabinets There is evidence that DIN 8953/8954 Household frozen storage cabinets has been used by the industry to evaluate the performance of blast cabinets. However, it has been phased out WALK-IN COLD ROOMS Introduction This section on test standards for walk-in cold rooms covers methodologies to assess the parameters and performance of both the components that impact on the energy performance of walk-in cold rooms, and the energy performance of the products themselves. Firstly, methods for testing of the insulation panels and insulated box are described. Subsequently, options for testing of the refrigeration system are 79 Source: 74 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

75 discussed. Testing methods for the various individual components are then covered, and lastly methods for testing the energy consumption of the entire product are considered. For the evaluation of refrigeration systems, standards described within other sections are also relevant. These include EN 327 for packaged systems ( ), and EN ( ) and EN ( ) for remote condensing systems European Technical Approval Guideline (ETAG) 021 and Relevance: framework for design of cold storage kits The ETAG 021 Cold storage premises kits is divided into two parts: Part 1 Cold storage room kits and Part 2 Cold storage building envelope and building kits covering specific aspects related to different intended uses. Part 2, covering products that might be constructed outdoors, has additional elements mainly relating to the need to weather-proof the structure. This guideline was established in the context of Directive 89/106/EEC on construction products ( ). European technical approvals are used to assess the suitability of a product for its intended use in cases where there is no harmonised standard, no recognised national standard and no mandate for a European standard and where the Commission feels, after consulting the Member States within the Standing Committee on Construction, that a standard cannot or cannot yet be prepared. The European Organisation of Technical Approvals (EOTA), which groups together the national approvals bodies, can draw up technical approvals guidelines in respect of a construction product or family of construction products, acting on a mandate from the Commission and after consulting the Standing Committee on Construction 81. The scope of the guideline covers cold storage kits whose components are predesigned and prefabricated by one or various manufacturers to be produced in series and three-dimensional prefabricated transportable rooms. Cold storage building kits contain at least the load bearing structure and wall and roof panels, or wall panels and roof (with ceiling panels). Some important points to note: The enclosure 82 is made out of sandwich panels with insulating cores 83. The kits follow pre-designed technical solutions for joints and assembly. For all premises, floors may be included depending on its characteristics. The guidelines cover cold stores intended to store products at temperatures below +15 C and above -40 C. As the rooms are designed for specific internal temperature intervals, these must be specified by the ETA applicant and declared in the ETA. The technical equipment (e.g. cooling systems and other electrical equipment) is excluded from the guidelines in both cases. 80 European Technical Approval Guideline 021. Cold storage premises kits. Draft Edition ec.europa.eu/enterprise/sectors/construction/documents/legislation/cpd/index_en.htm 82 The term envelope in this guideline refers to the waterproof layer and not to a structural part of the building. 83 In the context of the guideline, thermally insulating products are those with a declared thermal conductivity of less than 0.06W/m.K at +10 C. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 75

76 ETAG 021 covers required evaluation to comply with the EC Foodstuff Directive (91/43/ECC), the EC food contact material Directives (the Framework Directive 89/109/It. ETAG 021 specifies requirements for the construction, methods to validate the characteristics of the product and its fitness, judging methods and assumptions, and makes other recommendations (see Table 1-21). Some of them apply to both cold room kits and cold room building kits, while others are relevant only to one type of them: Table 1-21: Aspects considered in ETAG 021 scope to evaluate Cold rooms kits and Cold rooms building kits 84 Aspect CRK* CRBK** Mechanical resistance x x Safety in case of fire Reaction to fire x x Resistance to fire x x External fire performance Hygiene, health and environment Safety in use Dangerous substances release x x Vapour permeability x x Moisture resistance x x Fitness for contact with food and feedstuff x x Water tightness Air tightness x x Impact resistance x x Mechanical resistance Fixing resistance x x Mechanical resistance of wall, ceiling and floor panels x x Mechanical resistance of the cold storage building enclosures x x Eccentric loads resistance x x Slipperiness x x Safety against personal injuries by contact x x Safety against entrapment x x Safety against collapse (due to air pressure differences) x x Resistance to horizontal and provisions preventing falling due to changes in level or sudden drops Protection against noise Airborne sound insulation Impact sound insulation x x x x x 84 Source: European Technical Approval Guideline 021. Cold storage premises kits. Draft Edition Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

77 Aspect CRK* CRBK** Sound absorption x Energy economy and heat retention Thermal performance x Thermal resistance x Air permeability x x Water vapour permeability x x Thermal inertia x Durability, serviceability and identification Durability x x Serviceability x x Identification x x * Cold rooms kits ** Cold rooms building kits Within the documentation, it states that the assessment of the panels which are main components of cold storage rooms, i.e. composite panels with insulating cores, is primarily based on the draft harmonised technical specifications ETA-Guideline 016 "Self supporting light weight composite panels" or EN "Double metal faced insulated sandwich panels" ( ). EN 14509:2006 Relevance: to assess insulation properties of sandwich panels The main parameter of interest measured in respect to energy performance of the cold rooms is the thermal conductivity, λ, as described in Stakeholders confirmed that both ETAG 016 and 021 take EN as a reference concerning the general properties and characteristics of panels; therefore 85. Since October 2010, CE marking has been compulsory for all sandwich panels sold in the EU 86. This standard includes the specifications, evaluation and monitoring of factorymade, self-supporting, double skin metal faced insulating panels. It proposes a calculation method for the thermal transmittance of the panel. Due to the great variety of sandwich panel applications, profiles, adhesives, insulation core materials and production lines, different levels of mechanical performance can be achieved. The standard references EN to EN 13167, for specifications of testing different insulation materials. PUR is covered in EN BS EN 13165:2008 Relevance: to assess insulation properties of panel core material Thermal insulation products for buildings. Factory made rigid polyurethane foam (PUR) products. With the introduction of harmonized European Standard EN 13165, a new method of measurement and declaration of thermal conductivity (λ) 85 Source: ARNEG, INCOLD, Epta 86 Source: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 77

78 and thermal resistance was implemented to create a level playing field for insulation materials where permanent blowing agents are used. Hence, manufacturers of insulating panels must now declare the aged λ value BS EN :1991 Relevance: to assess performance of insulating box BS EN Electrically operated blood storage refrigerators defines standards for closed reach-in type refrigerators designed and equipped for the storage of whole blood and red cell components that need to be kept within specified limits of temperature. The refrigerators are intended for use in hospitals and blood collecting centres. Facilities for the storage of frozen blood products are excluded. The standard specifies that the insulation shall have a thermal transfer coefficient not greater than 0.35 W/(m 2 K) and should be vapour sealed. The preferred type of insulation is foamed in place, and the standard requires that if slab type insulation (blocks of pre-foamed insulation) is used, it should be bonded at joints and to both external and internal linings with a thermal break (for fire protection) between the inner and outer surfaces. Doors should be self-closing type with inner doors or flaps to reduce entry of ambient air to the compartment. A method of testing for temperature within the net storage volume of the cabinet on failure of the air recirculating fan to verify that either: a) the air temperature within the storage volume remains within the limits of 0 C to 8 C; or b) an audible and visual alarm operates. The temperature should be measured at the bottom and top of the storage volume using a calibrated recording device during the duration of the test. The operator should set the mean air temperature within the storage volume to maintain the temperature between +1 C and +7 C, and once reached, stop the air recirculating fan, continuing until whichever occurs first: a) until an audible and visual alarm is operated; or b) 24h passes. This test is known in the trade as the holdover test Agreement on the international carriage of perishable foodstuffs (ATP) Relevance: test method to assess insulation performance of the insulated box and refrigeration system, either as a whole system or individually ATP is the multi-lateral agreement between Signatory Countries (Contracting Parties) for overland cross border carriage of perishable foodstuffs. It ensures that vehicles used for this carriage meet agreed international standards. The standards apply to the bodywork (insulating box) and refrigeration units. The agreement also details the following aspects of interest: Classifications of equipment, based on operation storage temperature ranges (with a mean outside temperature of + 30 C and maintaining continuously temperature T i inside the empty insulated box): o Class A: T i may be chosen between + 12 C and 0 C inclusive; 78 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

79 PAS 57:2003 o Class B: T i may be chosen between + 12 C and - 10 C inclusive; o Class C: T i may be chosen between + 12 C and - 20 C inclusive. o Class D: T i is equal to or less than 0 C; o Class E: T i is equal to or less than - 10 C; o Class F: T i is equal to or less than - 20 C. In the case of classes A, B and C, any desired practically constant T i (in conformity with the standards defined above), while in the case of classes D, E and F a fixed practically constant T i (in conformity with the standards defined above). Procedures for testing the insulated enclosure and refrigeration equipment, either combined (within an insulated testing laboratory) or separately (insulated box tested within insulated laboratory, refrigeration unit measured under other accepted standard conditions). Hence refrigerating capacity of the refrigeration system can be calculated by attachment to a calorimeter box, and the cooling capacity matched to the heat load requirement of the insulated box (as measured under the test conditions). Specifications of the test include: o K coefficient measured either by the internal cooling method or by the internal heating method; o conditions in the testing laboratory (such as air flow; o temperature measuring points; o period of test; and o parameter variances permitted. For test procedure details, please see Annex 1-1, Relevance: to assess performance of insulating box PAS 57:2003 Cellar cooling equipment Procedure for determining performance and calculating energy efficiency defines procedures and conditions for measuring the performance of cellar cooling equipment and calculating the energy efficiency, expressed as a COP, providing a means for comparing product energy efficiency. Cellar cooling equipment is a refrigeration system designed to maintain an indoor environment at a condition suitable for the storage of chilled beverages, typically +10 C to +12 C. The standard specifies procedures for determining the performance and energy efficiency of cellar cooling equipment with a capacity between 2 kw and 12 kw, at a standard rating condition of +10 C air onto the evaporator and +32 C air onto the condenser, using air-cooled condensers categorized as either: a) a packaged system, comprising all components mounted on one base for through the wall installation; or b) a split system, with the equipment supplied in two parts (evaporator and condensing unit) to be connected on site; or c) a remote system, with equipment supplied in three parts (evaporator, compressor/receiver unit and condenser) to be connected on site. All components supplied as part of the equipment shall be included in the evaluation. The standard specifies the conditions to be maintained in two rooms, Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 79

80 Test room A which will contain the condensing unit, consisting of the compressor, condenser, liquid receiver (where fitted), filter drier, or compressor/receiver set plus air cooled condenser or outdoor part of the packaged system, and Test room B (calorimeter room) which will contain the evaporator and expansion valve (where fitted to the evaporator). In addition, piping lengths and dimensions are specified for the split and remote system types. The system cooling capacity and energy consumption are measured to provide the COP, and the requirements for an evaluation report are set out AHRI 1251 (SI) (and AHRI 1250 (I-P)) Relevance: to assess energy consumption of whole product AHRI 1251 (SI units) Performance rating of Walk-In Coolers and Freezers applies to walk-in coolers and freezers, to rooms where unit cooler and condensing units are integrated, comprising a single package, to rooms where unit cooler (integral), and to those where the condensing unit is separated, either indoor or outdoor (remote, or split ). The control system may be integral, but if this is not the case the performance of the control system should be tested as well (normally by a separate party). The standard defines a method that evaluates the refrigeration system and the walk-in box heat load separately. This standard does not apply to: rooms for telecommunication switch gear or other equipments that need to be cooled; enclosures for medical, scientific or research purposes; performance testing of large parallel rack refrigeration systems (condensing units). The standard sets out a testing procedure that allows the calculation of the Annual Walk-in Energy Factor (AWEF). Annual Walk-in Energy Factor (AWEF). A ratio of the total heat, not including the heat generated by the operation of refrigeration systems, removed, in watt-hours, from a walk-in box during one year period of usage for refrigeration to the total energy input of refrigeration systems, in watt-hours, during the same period. 87 Conditions for calculation of Standard Rating are defined for product configurations (indoor/outdoor condensing unit; fixed capacity matched, two capacity matched and variable capacity matched refrigeration systems), and these ratings should include its associated power input and COP, and there is a requirement to calculate the Application Rating, consisting of a Capacity Rating plus the associated power input and COP. The standard then sets out equations to calculate the box heat load for various product configurations (indoor/outdoor condensing unit; fixed capacity matched, two capacity matched and variable capacity matched refrigeration systems). The walk-in box load is comprised of a high load period (BLH) of the day corresponding to frequent door openings, product loading events, and other design load factors, and a low load period of the day (BLL) corresponding to the minimum 87 AHRI Standard for Performance Rating of Walk-In Coolers and Freezers Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

81 load resulting from conduction, internal heat gains from equipment that is not related to the refrigeration system, and infiltration when the door is closed. Both the BLH and BLL are defined as a linear relationship with outdoor ambient temperature. This relationship accounts for the influence of outdoor ambient on the conduction and infiltration loads for a typical walk-in box. 87 Finally, equations to calculate the AWEF for various system configurations are presented US test procedures for walk-in coolers and freezers Relevance: minimum insulation standards for product components Test methods prescribed to confirm achievement of minimum standards (see ): The R-value shall be the 1/K factor multiplied by the thickness of the panel. The K factor shall be based on ASTM test procedure C For calculating the R-value for freezers, the K factor of the foam at 20 F (+6.7 C) (average foam temperature) shall be used. For calculating the R-value for coolers, the K factor of the foam at 55 F (+12.7 C) (average foam temperature) shall be used US DOE proposed test procedures for walk-in coolers and freezers Relevance: development of method to assess energy consumption of whole product across the market and implement minimum standards The US Energy Independence and Security Act of 2007 enacted on December 19, 2007, establishes energy conservation standards for certain consumer products and commercial and industrial equipment, including walk-in cold rooms and walkin freezers. The DOE s Building Technologies Program has been developing proposals for testing energy consumption of walk-in cooler and freezer rooms. A Notice of Proposed Rulemaking was published in January 2010, and a public meeting held in March 2010 to discuss the options. DOE considers that there are two distinct components of a walk-in cooler or walkin freezer, the envelope (enclosure), in which items are stored, and the refrigeration system that cools the space inside the enclosure. The enclosure isolates the interior and all energy-consuming components that are not part of the refrigeration system (walls, floors, ceilings, seals, windows, doors, lighting, automatic door motors and anti-sweat components, among others) from the ambient, external environment. The definition of the refrigeration system is proposed as being refined to: Refrigeration system means the mechanism used to create the refrigerated environment in the interior of a walk-in cooler or freezer, consisting of a packaged system where the unit cooler and condensing unit are integrated into a single piece of equipment, or a split system with separate unit cooler and condensing unit sections, or a unit cooler that is connected to a multiplex condensing system; Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 81

82 and including all controls and other components integral to the operation of this mechanism. 88 The figure below provides an overview of the elements to be covered by the proposed test procedure. Figure 1-23: US DOE walk-in cold room test procedure proposal 88 The DOE initially considered a single test procedure but changed its approach after receiving input from interested parties. Subsequent stakeholders feedback indicated that using a single test procedure (an earlier proposal) was not a viable approach, because: It could be burdensome to perform the test. The enclosure and refrigeration system are typically manufactured separately. The assembler or installer could be required to demonstrate compliance. It would be difficult to enforce testing requirements if the walk-in is assembled in the field. As shown in Figure 1-23, the current recommendations of the DOE for evaluation of these appliances are to assess the enclosure and refrigeration system separately. The proposal also considers enforcing testing of a basic model, through which the performance of other similar products can be performed without conducting the full test, and instead using a calculation methodology based on a Daily Energy Consumption Coefficient (DECC) for the enclosure to assess energy consumption for those products grouped under one of the basic models. The DECC parameters might include: Wall surface area Non-glass door surface area Glass display door surface area Glass wall and inset window surface area Opening of doors (and effectiveness of infiltration reduction devices) 88 US DOE Walk-In coolers and freezers energy conservation standards public meeting presentation slides. Available at: www1.eere.energy.gov/buildings/appliance_standards/commercial/pdfs/wicf_prenopr_publicmeeti ng_slides_final.pdf 82 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

83 Electrical energy consumption due to devices including, but not limited to: lights, anti-sweat heaters, and motors to drive air mixing fans DOE originally proposed to allow manufacturers to develop Alternative Efficiency Determination Methods (AEDMs) for calculating energy consumption of units using computer modelling but stakeholders objected, as they thought it: Could be expensive and time-consuming for manufacturers to develop. Could benefit some manufacturers unfairly. May not provide consistent information to end users. In the proposed test standard, specific elements and characteristics of the enclosure and the refrigeration system will require tests. Insulation: o Ageing: to calculate the foam R-value 89, a version of ASTM C is proposed to be used with blown foams (that considers the ageing factor through time accelerated methods), and ASTM C for other sorts of foam. o Water absorption in foam: the insulating capacity of foams decreases with the quantity of water absorbed. The testing in this regard should include: determination of water absorption rate (by means of accelerated methods), maximum absorption, quantification of the relationship between water absorption and insulation performance. Due to the complexity of the methods to evaluate these characteristics, DOE does not propose any standard. Air filtration: being a major cause of energy loss, DOE proposes to use: o Gas tracer method: based on ASTM-E and applicable to steady state, with the following comments: preferred use of concentration decay method among all methods proposed in ASTM-E741-06; use of carbon dioxide as the most appropriate tracer gas; air change method is more suitable than air change flow. DOE proposes that measurements respect homogeneity of the space; measurements should take place in conditions similar to those of operation; and, the test should be made with all doors closed and the results reported in units of changes per hour. The refrigeration system: 89 Heat transfer coefficient Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 83

84 o The test procedure computes the AWEF. DOE refers to AHRI 1250 standard (see ) as the testing standard to adapt PROCESS CHILLERS EN 14511:2007 Relevance: Industrial process chillers The EN Air conditioners, liquid chilling packages and heat pumps with electrically driven compressors for space heating and cooling - Terms and definitions, test conditions, test methods and requirements, specifies the terms, definitions, test conditions, methods and requirements for the rating and performance of air- and water-cooled air conditioners, liquid chilling packages, airto-air, water-to-air, air-to-water and water-to-water heat pumps with electrically driven compressors when used for space heating and/or cooling. Liquid chilling packages are typically tested with this standard, being not restricted to comfort equipment. It was stated by stakeholders that the conditions specified within this standard for testing are extreme, and sometimes not a realistic representation of actual working conditions EN 15218: pren Relevance: Air conditioning and liquid chillers EN 15218:2006 Air conditioners and liquid chilling packages with evaporatively cooled condenser and with electrically driven compressors for space cooling. Terms, definitions, test conditions, test methods and requirements. is also of relevance. The pren 14825:2009 Air conditioners, liquid chilling packages and heat pumps, with electrically compressors, for space heating and cooling- Testing and rating at part load conditions and calculation of seasonal performance provides testing methods for refrigeration and air-conditioning equipment considering part-load conditions and seasonal performance AHRI 550/ Relevance: Industrial process chillers (vapour compression) The AHRI 550/ Standard for performance rating of water-chilling packages using the vapor compression cycle establishes definitions, test requirements, rating requirements and minimum data requirements for published ratings, marking and nameplate data; and conformance conditions. Scope: This standard applies to factory-made vapour compression refrigeration water-chilling packages, including one or more hermetic or open drive compressors 90. These equipments include: water-, air- or evaporatively-cooled condensers 90 AHRI Standard 550/ Standard for performance rating of water-chilling packages using the vapor compression cycle Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

85 air-, water-cooled heat reclaim condensers packages supplied without a condenser Test requirements: The tests required for this standard shall be conducted in accordance with Appendix C of the AHRI 550/ standard. Rating conditions: Table 1-22 specifies standard rating conditions for all waterchilling packages. Table 1-23 presents part-load rating conditions defined by ANSI/AHRI 550/ to permit the development of part-load performance over a range of operating conditions. Rating requirements: The minimum rating requirements include the following: Net refrigerating capacity, refrigeration tons (RT) [kw] Total power input to chiller, bhp or kw, as applicable Energy efficiency, expressed as EER, COP or kw/ton Evaporator Fouling Factor Chilled water entering and leaving temperatures, F [ C], or leaving water temperature and temperature difference, F [ C] Evaporator water pressure drop (inlet to outlet), psi or ft H 2 O [kpa] Chilled water flow rate, gpm [L/s] Nominal voltage, V, and frequency, Hz, for which ratings are valid Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 85

86 Table 1-22: Standard rating conditions of water chilling packages Water-cooled Evaporatively-cooled Air-cooled Condenser water Entering +85 F C Flow rate Water-side 3.0 gpm/tonne h*ft 2 * F/Btu L/s per kw Condenser fouling factor allowance m 2 * C/W Air-side 0.0 ft 2 * F/Btu 0.0 m 2 * C/W 0.0 h*ft 2 * F/Btu 0.0 m 2 * C/W Entering air Dry-bulb F C Wet-bulb +75 F C Evaporator water Leaving F +6.7 C F +6.7 C F +6.7 C Flow rate 2.4 gpm/tonne L/s per kw 2.4 gpm/tonne L/s per kw 2.4 gpm/tonne L/s per kw Evaporator fouling factor allowance Water-side h*ft 2 * F/Btu m 2 * C/W h*ft 2 * F/Btu m 2 * C/W h*ft 2 * F/Btu m 2 * C/W Evaporator fouling factor allowance Saturated discharge Liquid refrigerant Barometic pressure F C F C F C F C F C F C in Hg kpa in Hg kpa in Hg kpa 86 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

87 Table 1-23: Part-load conditions for rating ANSI/AHRI Relevance: Industrial process chillers (absorption) The ANSI/AHRI Absorption water chilling and water heating packages establishes: definitions; test requirements; rating requirements; minimum data requirements for published ratings; marking and nameplate data; and conformity conditions. Scope: This standard applies to water-cooled single effect steam and hot water operated water chilling units, water-cooled double-effect steam and hot water operated water chilling units, and double-effect direct-fired (natural gas, oil, LP gas) water chilling/heating units. Water is the refrigerant and LiBr (lithium bromide) the absorbent. This standard does not apply to air-cooled applications, heat pump applications, exhaust gas fired applications and non-standard units. Test requirements: The tests required for this standard shall be conducted in accordance with Appendix C of ANSI/AHRI standard. Rating conditions: Table 1-24 specifies standard rating conditions of absorption water chilling and water heating packages. Table 1-25 presents part-load rating conditions defined by ANSI/AHRI to permit the development of part-load performance over a range of operating conditions. Rating requirements: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 87

88 The minimum rating requirements include the following: Net refrigerating capacity, tons [kw] Total Energy Input to the chiller in MBH 91 [kw], as applicable Direct Fired, MBH [kw] based on Higher Heating Value Indirect Fired, MBH [kw] Chiller Efficiency, expressed as COP or MBH/ton Evaporator Fouling Factor, as stated in Table 1 of the standard Chilled water entering and leaving temperatures, F [ C] (as stated in Table 1 of the standard), or leaving water temperature and temperature difference, F [ C] Evaporator water pressure drop (inlet to outlet), psi or ft H 2 O [kpa] Chilled water flow rate, gpm [L/s] Average electrical power consumption, kw [kw] for all auxiliary components including solution and refrigerant pumps, purge, control panel, burner fan, burner controls, etc. Power required by system water pumps shall be excluded. Absorber/condenser water pressure drop (inlet to outlet), psi or ft H 2 O [kpa] Any two of the following: o Entering absorber/condenser water temperature, F [ C] o Leaving absorber/condenser water temperature, F [ C] o Water temperature rise through the absorber/condenser, F [ C] Absorber/condenser water flow rate, gpm [L/s]. Fouling Factors, as stated in Table MBH is the expression of BTU's (British Thermal Units) in thousands. 88 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

89 Table 1-24: Standard rating conditions of absorption water chilling packages Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 89

90 Table 1-25: Part-load Rating conditions of absorption water chilling packages CAN/CSA-C Relevance: Industrial process chillers The CAN/CSA-C Performance Standard for Rating Packaged Water Chillers applies to factory-designed and prefabricated water-cooled chiller/heater units, single-effect indirect-fired by steam or hot water, and double-effect, both indirectfired by steam or hot water and direct-fired by oil, natural gas or LP gas; water is the refrigerant and lithium bromide is the absorbent. This standard does not apply to absorption chiller/heater units with air-cooled condensers, nor to applications employing heat pumping or exhaust gas firing. 90 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

91 AS/NZS 4776: Relevance: Industrial water chillers The AS/NZS 4776:2008 Liquid-chilling packages using the vapour compression cycle standard aims to establish a method to rate the performance of factorymade liquid chilling packages using the vapour compression cycle. The scope of the standard includes: air- and water-cooled liquid-chilling packages of cooling capacity 350kW and above. The AS/NZS does not cover: liquid-chilling packages driven by other than electrical motors; air-cooled liquid-chilling packages with centrifugal fans; liquid-chilling packages with remote condensers; and liquid-chilling packages for fluids other than water. This standard is linked to a MEPS (see ) REMOTE CONDENSING UNITS EN 13771:2003/ EN 13771:2007 Relevance: Remote condensing unit, compressor and condenser EN :2003 Compressor and condensing units for refrigeration performance testing and test methods for refrigerant compressors applies to refrigerant compressors and describes a number of selected performance test methods. These methods provide sufficiently accurate results for the determination of the refrigerating capacity, power absorbed, refrigerant mass flow, isentropic efficiency and the coefficient of performance. This European Standard applies only to performance tests conducted at the manufacturer's works. EN : 2007 Compressor and condensing units for refrigeration. Performance testing and test methods. Part 2: Condensing units. This part of EN applies only to condensing units for refrigeration and describes a number of selected performance test methods. These methods provide sufficiently accurate results for the determination of the refrigerating capacity, power absorbed, refrigerant mass flow and the coefficient of performance EN 13215:2000 Relevance: Remote condensing unit EN 13215:2000 (ISO 917:1989) Condensing units for refrigeration. Rating conditions, tolerance and presentation of manufacturer s performance. This standard is applicable to equipments with positive-displacement compressors and it aims to specify rating conditions, tolerances and presentation of manufacturer s performance data, usable for comparison of different units. The performance of 92 Source: Standard Australia/Standard New Zealand :2008. Liquid-chilling packages using the vapour compression cycle Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 91

92 the units (related to the refrigeration capacity) includes correction factors and based on full load operation 93. Table 1-26 Standard reference points specified in EN 13215: ASHRAE Standard Relevance: Packaging condensing unit, compressor and condenser The ASHRAE Methods of Testing for Rating Positive Displacement Refrigerant Compressors and Condensing Units (ANSI approved) applies to the methods of testing for rating single-stage positive-displacement refrigerant compressors and condensing units that do not have liquid injection and are operated at subcritical (saturated) temperatures of the refrigerant. It also applies to the methods of testing for rating single-stage positive-displacement refrigerant compressors and condensing units that incorporate liquid injection that is controlled by a steady flow rate method and are operated at subcritical (saturated) temperatures of the refrigerant ISO/R 916:1968 Covers the determination of the technical performance of a refrigerating system, but not the functional duty of a complete installation or the performance of its individual components. The term "refrigerating system" implies the conventional vapour compression type consisting of compressing, condensing and evaporating apparatus, together with the interconnecting piping and the accessories necessary to complete the refrigerant circuit. 93 Source: 92 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

93 STANDARDS RELATED TO THE DESIGN, USE AND SAFETY OF PRODUCTS EU EN 631-1:1993 Gastronorm Relevance: Blast cabinets, service cabinets The size of refrigeration equipment used for catering is normally standardised according to Gastronorm format. This is used by the European Committee of Standardization under the reference EN 631-1:1993 Materials and articles in contact with foodstuffs. Catering containers. Dimensions of accessories and supports. According to this, the trays can be used for storage, transportation, handling, service, etc. The basic size is the GN1/1 with a capacity equal to 530mm x 325mm. However there is a big range of sizes as per the following table. Table 1-27 Gastronorm standardised size for kitchen related equipment according to EN 631-1:1993 Format Surface area (mm) GN 2/1 530 x 650 GN 1/1 530 x 325 GN 2/3 352 x 325 GN 1/2 265 x 325 GN 1/3 176 x 325 GN 2/8 132 x 325 GN 2/4 530 x 162 GN 1/4 265 x 162 GN 1/6 176 x 162 GN 1/12 88 x 162 GN 1/9 176 x 108 GN 2/ x 108 GN 1/18 88 x EN 1672:1997 Food processing machinery hygiene requirements Part 2: Hygiene requirements Relevance: Service cabinets, blast cabinets, walk-in cold rooms Provides details on verification tests and on what user instructions (provided by manufacturers) need to cover, specifying the cleaning regimes and materials and safe methods of dismantling, cleaning (disinfecting) and rinsing the machine, including any internal pipework EN ISO 14159:2002 Relevance: Service cabinets, blast cabinets, walk-in cold rooms The standard specifies hygiene requirements, both for the equipment and the information to be provided by the manufacturer regarding the intended use. It Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 93

94 applies to all types of machines and associated equipment used in applications where hygiene risks to the consumer of the product can occur EN :2010 Relevance: Service cabinets, blast cabinets, ice-makers, and beverage and dessert appliances The international safety standard EN IEC Household and similar electrical appliances Safety is composed of two distinct sections. Part 1 General requirements, describes general requirements common to all the electric motor appliances. Part 2 addresses various specific products. Those applicable to ENTR Lot 1 are described in the following paragraphs. The EN IEC :2006 Household and similar electrical appliances safety part 2-24: particular requirements for refrigerating appliances, ice cream appliances and ice-makers deals with the safety of refrigerating appliances for household or similar use, ice-makers incorporating a motor-compressor, icemakers intended to be incorporated in frozen food compartments, refrigerating appliances and ice-makers for use in camping, touring caravans and boats for leisure purposes. Appliances intended to be used in shops are within the scope of this standard. The EN IEC :2004 Household and similar electrical appliances safety part 2-34: particular requirements for motor compressors deals with the safety of sealed motor-compressors (hermetic and semi-hermetic types), their protection and control systems. They are intended for use in equipment for household and similar purposes and conform with the standards applicable to such equipment. Examples of equipment which contain motor compressors are refrigerators, food freezers and ice-makers. The EN IEC :2005 Household and similar electrical appliances safety part 2-89: particular requirements for commercial refrigerating appliances with an incorporated or remote refrigerant condensing unit or compressor specifies safety requirements for electrically-operated commercial refrigerating appliances that have an incorporated compressor or that are supplied in two units for assembly as a single appliance in accordance with the manufacturer s instructions (split system). Scope: Appliances that are within the scope of this standard are: refrigerated service cabinets, blast chillers and blast freezers (refrigerated display cabinets - covered in the preparatory study TREN Lot 12, service counters and self-service counters are also covered) 94. This standard does not apply to: commercial ice-cream appliances, commercial icemakers, cold rooms, domestic refrigerating appliances, industrial refrigerating systems, motor-compressors (IEC described previously), commercial dispensing appliances and vending machines (IEC ), and multiple refrigerated chambers with a remote compressor. Appliances with a charge of more than 150 g of flammable refrigerant in each separate refrigerant circuit are not covered by this standard. For appliances with a charge greater than 150 g of 94 IEC Website: 94 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

95 flammable refrigerant in each refrigerant circuit and for the installation, ISO 5149:1993 may be applied. Requirements: As far as is practicable, this standard deals with the common hazards presented by appliances within the scope of EN IEC : EN :2004 Relevance: Walk-in cold rooms The standard specifies lighting requirements for indoor work places which meet the needs for visual comfort and performance. All usual visual tasks are considered, including display screen equipment (DSE). It covers lighting design criteria, schedule of lighting requirements and verification procedures. It does not specify lighting requirements with respect to the safety and health of workers at work, although the lighting requirements as specified in this standard usually fulfill safety needs, and is not applicable for the lighting of outdoor work places and underground mining FR NF AC D40-003:2006 Relevance: Blast cabinets, service cabinets NF AC D40-003:2006 Equipment for collective restaurant refrigerating equipment. General design and construction rules for ensuring hygiene in use. This document establishes some manufacturing rules to decrease hygiene-related risks associated with restaurant equipment, including blast and service cabinets. The conditions expressed in the original text are summarised below: Environment Mean temperature: > +24 C, Instant temperature: +25 C (± 4K) Testing conditions (performance testing): cabinets Testing load o Foodstuff type: smashed potatoes: potatoes paste flakes (11.5%), water (87.7%) and salt (0.8%). Percentages are expressed in mass. The salted water is heated up to 75 to 80 C. The potatoes are added and mixed. This mixture is added to package type trays and lidded. This preparation can be used only once. o o o o Package type tray: the disposable trays made of carton with polypropylene weight 1.8kg. Their size corresponds to GN ½. The tray lid is the material as the tray itself. M-package: package type including fixed temperature measuring equipment. Weight: the testing weight shall be the one declared by the equipment manufacturer according to the cycle with a tolerance of 5%. Number of trays and distribution: the packages or testing material are placed in the trays corresponding to the nominal load. At least 10 temperature probes shall be in use. There shall be at least one Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 95

96 o package per tray. They shall be arranged alternately from front to back or from right to left. The temperature of the load shall be between +63 C to +80 C. Refrigerant charge o Loading o The remote condensing unit should be located outside the testing room. The distance between the equipment and the condensing unit shall be registered. The same rule applies to equipment using cryogenic material. The conditions for evaluation of remote blast cabinets are described in section 0. The temperature inside the equipment shall be in the same as the room conditions. The loading shall be done as fast as possible. Temperature registration o o The room temperature and the temperature of the packages shall be registered every 5 minutes. To determine the initial and final temperature, the data collection shall be done every minute is possible. Reference temperature o o Initial temperature: +63 C. Final temperature: +10 C for chilling equipment, -18 C for freezing equipment. Required results o o o Testing period of time: the initial time is the time when the package s mean temperature is equal to the initial reference temperature. While, the final time shall correspond to the instant when the package s mean temperature correspond to the final reference temperature. In the case of blast chilling equipment, the tolerance will be of 1.5 C. The test will be satisfactory if: - The testing material temperature decreases from C to +8.5 C in 120 min (+5%) or less. - The temperature of the coldest package shall be greater than - 1 C. In the case of blast freezing equipment, the test will be satisfactory if: - The testing material temperature decreases from C to C in 4.5 hours (+5%) or less. o In the case of combined blast equipment, the test will consist of: - 2 tests conducted with the appropriate conditions according to the type of cycle. - the required results are from the chilling and freezing cycles. Performance Testing: vacuum test (remote condensing units) 96 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

97 This section describes the procedure of remote blast cabinets testing. The test can be performed either in a testing room or in-site. Temperature: o o for vapour compression cycles: the test is done under 2 room temperature conditions: +20 C (±4K) and +35 C (±4K). for cryogenic systems: the test is done under the room temperature. This temperature has to be registered. Relative humidity: not considered. Test procedure: 3 temperature probes shall be used to measure the temperature of the condensing unit and of the room. The measurement shall be done every 5 minutes. Reference temperature: o o Initial: +20 C and +35 C or the room temperature in-site. Final: +20 C for blast chilling, +35 C for blast freezing and 40 C for cryogenic cabinets. Testing time, the test will end once the probe temperature measures correspond to the final reference temperature. The time in testing room conditions will be used as reference for the in-site testing time. Further information on protocol for service cabinets is expressed in section DE VDMA Operation and use of refrigerated display cabinets Relevance: Service cabinets, walk-in cold rooms, blast cabinets Relates to the operation and use of refrigerated cabinets and the corresponding refrigeration devices, and details possible measures for maintaining the safety temperatures for refrigerated cabinets, and the optimum conditions for energyefficient operation DE VDMA Energy efficiency of refrigerating systems Part 1: Contribution of refrigerating and air conditioning systems to climate protection Improvement of energy efficiency Reducing greenhouse-related emissions Part 2: Requirements for system design and components Part 3: Guideline for an improved energy efficiency in cold storages Part 4: Supermarket refrigeration Part 5: Industrial refrigeration Part 6: Refrigeration in air conditioning systems Part 7: Control and energy management Part 8: Components Heat Exchangers These standards describe means to improve refrigeration system efficiency and reduce environmental impacts, both in respect to overall system design and selection of components, as well as more in-depth analysis and recommendations for specific industrial sectors US NSF/ANSI 7:2009 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 97

98 Relevance: Blast cabinets, service cabinets, walk-in cold rooms NSF/ANSI Standard 7:2001 Commercial Refrigerators and Freezers provides requirements for minimum food protection and sanitation requirements for the materials, design, manufacture, construction and performance of foodstuff storage equipments for refrigeration and freezing, not limited to service cabinets, walk-in cold rooms, and blast cabinets, among others. This standard does not provide installation requirements STANDARDS AFFECTING THE USE OF REFRIGERANTS EU EN 378:2009 Relevance: Refrigerating systems, refrigerants The EN 378:2009 Refrigerating systems and heat pumps. Safety and environmental requirements. Design, construction, testing, marking and documentation includes within its scope piping, components and materials and additional equipment in direct association with those systems. It also states requirements for testing, commissioning, marking and documentation. If the heat transfer fluid is liquid at atmospheric pressure, the requirements for its circuits are excluded from this standard but not for those belonging to safety devices associated with the refrigerant system. This standard does not concern water, air refrigerant systems or systems to be used in potentially explosive atmospheres. It also specifies the requirements for stationary and mobile refrigerating systems, including heat pumps. EN 378:2009 only includes systems whose refrigerants are listed in the Annex of EN 378-1:2008 as long as a safety class is not assigned. EN defines some basic safety standards for refrigerating systems, such as limits for refrigerant charge depending on the size of the room, due to the flammability or toxicity of the substances. Part 1, "basic requirements, definitions, classification and selection criteria" provides definitions of certain terms used in the standard. It also provides a classification system according to: Usage of the premises: o o o category A: rooms, parts of building or buildings in which persons may sleep or may not have total freedom of movement and where persons are not aware of the safety measures to be applied. Such premises include hospitals, courthouses and prisons, supermarkets, schools, railway stations, etc. and thus are public buildings; category B: rooms, parts of building or buildings in which certain persons may be aware of the general safety measures to be applied. Such premises include production plants, commercial premises, etc; category C: rooms, parts of building or buildings in which all persons present are trained in the general and specific safety measures to be applied. Such premises include specific production plants, cold stores, etc. Refrigerants are classified according to their flammability and toxicity: 98 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

99 o group L1 (non-toxic, non-flammable refrigerants) forming category A1; o o group L2 (slightly flammable refrigerants) comprising the categories A2, B1 and B2; group L3 (toxic, flammable refrigerants) comprising the categories A3 and B3. Annex E contains information on refrigerants and indicates their characteristics (molecular mass, flammability limits, GWP, ODP, etc.) DE VDMA Operational requirements for refrigerating systems Part 1: Ammonia refrigerating systems Part 2: Refrigerating systems with non-flammable refrigerants (Safety group A1 according to EN 378) Following the Meseberger resolutions of the government of the Federal Republic of Germany in August 2007, a process was initiated that has led to the recent development of new standards for refrigeration systems, and the use of certain components within these systems (for the use of heat exchangers for example) 95. These will be discussed in more detail within the technical annex on refrigeration systems US ASHRAE Standard Relevance: Refrigerants The ASHRAE Designation and Safety Classification of Refrigerants intends to establish simple ways of referring to commonly used refrigeration to avoid mentioning chemical names, formulas or trade names. The scope of this standard includes a uniform system for assigning reference numbers without being ambiguous and safety classifications to refrigerants. The safety classification is based on the toxicity and flammability data. This standard does not recommend using any particular refrigerant or blend SUMMARY OF EXISTING STANDARDS Considering the products discussed in subtask 1.1 of ENTR Lot 1 study, there are no EN or international use-phase testing standards covering the whole range of products (Table 1-28). Therefore, a need is identified for providing harmonised test standards. More detailed conclusions by product group are discussed in the following sections. 95 VDMA (German Engineering Federation) Einheitsblatt: Betriebliche Anforderungen an Kälteanlagen (Functional requirements for refrigeration systems) (2008). Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 99

100 Table 1-28: Summary of identified performance testing standards Product category EU or MS standards Third country standards Service cabinets EN 441:1995 EN ISO 23953:2005 (CECED Italy adaptation to be completed) ANSI/AHRI 1200:2008 ASHRAE 72:2005 CSA C (plug-in only) Blast cabinets DIN 8953/8954 and EN 328 NSF/ANSI 7:2009 Walk-in cold rooms Chillers - packaged Remote condensing units n/a: No testing standards Service cabinets Blast cabinets ETAG 021 and 016 (design of insulated enclosure) EN14509 (insulation panels) EN (packaged chillers) pren 14825:2009 (under development) EN 13771:2003 / EN 13771:2007 EN AHRI 1251 (SI) 2009 US DOE discussing adapting the ANSI/AHRI 1250:2008 or the ASHRAE 72:2005 standard AHRI 550/590:2003 (packaged compression chillers) ANSI/AHRI 560:2000 (packaged absorption chillers) AS/NZS 4776: 2008 CAN/CSA-C ASHRAE ASHRAE (packaged) Regarding testing methodologies, there are plenty of EU and international standards covering the performance of these appliances. EN 441 is also currently in use in certain MS, and is the basis of the UK ECA and DK ETL. Service cabinet performance data quoted in ENTR Lot 1 refer to this test standard. EN ISO 23953:2005 is currently being analysed to be evaluated by CECED Italia to establish its adaptability to service cabinets, beyond display cabinets. This mainly requires adaptation of the door/lid openings pattern and M-package loading. EFCEM has taken responsibility for the development of a harmonised standard in the EU. AHRI 1200 (in the US) is not commonly used in EU. Most of the identified thirdcountry standards deal with household equipment. Broadly speaking, an analysis of applicability of household standards (such as EN 153:2006 or EN ISO 15502:2005) and display equipment standards (EN ISO 23953) to solid-door professional equipments is needed in consultation with industry, to identify the most suitable approach for ENTR Lot 1. This variety of options provides a good basis from which to develop a harmonised standard within the EU. Although uncommon, remote service cabinets pose a greater challenge when measuring electricity consumption. Indeed, remote service cabinets need to receive a certain amount of refrigerating energy from a remote condensing unit in order to operate and are therefore not considered as standalone products. In the EN ISO standard on refrigerated display cabinets ( ) the energy consumption is given by the total energy consumption in kwh per 24h period (TEC). This approach is similar to what is proposed in the ANSI/AHRI 1200:2008 standard ( ). For blast cabinets there are no specific standards regarding energy efficiency or performance in the EU (nor in third countries). This may be due to the current 100 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

101 focus on cooling performance (to meet food hygiene requirements) rather than energy efficiency. It was mentioned by stakeholders that EN ISO is considered as the best alternative to be used for testing blast cabinets. However, due to the particular cycle of activity (discrete peaks of consumption in order to cool down food temperature) of this type of equipment, the instrument used in representation of the foodstuff during testing should be modified to evaluate correctly the equipment. Also, the functioning conditions of the equipment are well specified in the NF AC D , and can be considered during the energy testing methodology application. However, it was mentioned by stakeholders that the feasible upper limit for testing is equipment of 60kg due to material cost limits. There is some prior development of performance testing standards on which to develop a harmonised approach in the EU. The German standard DIN 8953/8954 and the EN 328 used to determine the capacity of refrigerating equipments are options for these products Walk-in cold rooms AHRI 1251 (SI) 96 can be used currently to evaluate the energy performance of walk-in cold rooms as a whole produce. Computerised modelling may be an alternate route to assessing performance, but this approach is currently thought to be impractical by the US DOE. In terms of individual components, ETAG 021 specifies standards to be taken into account when designing the insulating enclosure of walk-in cold rooms, including thermal performance, thermal resistance, air permeability, water vapour permeability and thermal inertia. For the insulating panels, EN 14509:2006 (itself referencing EN 13165) is the reference standard for calculating the aged thermal performance of insulation material. For the evaluation refrigeration systems (to be connected to insulated enclosures), standards described within other product sections are also relevant. These include EN 327 for packaged systems ( ), and EN ( ) and EN ( ) for remote condensing systems. Another example of refrigeration system testing (for cellar coolers) is provided by PAS 57. The ATP agreement provides an example of methods to test an insulated enclosure and refrigeration system as a whole product, and also testing and matching of these two elements of a refrigerated cold storage space as separate components. 96 International System units Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 101

102 Process chillers Classification by temperature range (-25 C/-8 C; -12 C/3 C; 2 C/15 C) seems to be suitable for discriminating final use of chillers. Some stakeholders stated that the power capacity and size are common classifications because they provide the necessary information about energy and working capacity (even if they reach the same temperatures). Other temperature ranges are used by Eurovent to define standard brine conditions: 0 C/-5 C (medium brine) and -10 C/-15 C (low brine). Existing test standards apply only to packaged chiller energy performances when it comes to measuring their efficiency (e.g. EN part 1 to 4 and CEN TS 14825, AHRI 550/590:2003, CAN/CSA-C743-02). The existing EU standards for testing of chillers seem to cover the same information as their US equivalents; there is currently no identified need to modify the existing EU standards (EN 14511:2007) in light of US standards Remote condensing units The use of the methods stated in EN :2007 for testing remote condensing units in the EU has been identified. The use of the testing conditions stated in EN 13215:2000 to present manufacturer s performance data is also a common practice in the EU. This standard provides rating conditions that can be used for comparison of different appliances, even though manufacturers claim that the conditions might not be accurate. 102 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

103 1.4. EXISTING LEGISLATION AND VOLUNTARY AGREEMENTS The aim of this section is to give an overview of existing legislation and agreements (such as voluntary programmes) covered by ENTR Lot 1, at the EU level, in EU MS and in third countries for all products and components (such as motors and refrigerants) and also at a global level for refrigerants. Appliances covered by ENTR Lot 1 are electrical products containing a refrigerant fluid (and potentially ozone-depleting substances) and many European Directives apply to these products. These Directives can be classified into environmental, energy and safety legislation. EU legislation therefore covers ecodesign, WEEE, refrigerants, construction, and health and safety. Box 1-5 lists the relevant European legislation in the scope of ENTR Lot 1. Box 1-5: European legislation in the scope of ENTR Lot 1 SCOPE Environmental Legislation Entire product LEGISLATION Waste Electrical and Electronic Equipment Directive 2002/96/EC (vending machine) Restriction of the use of certain Hazardous Substances in electric and electronic equipment Directive 2002/95/EC (vending machine) Refrigerating Fluids Ozone Depleting Substances Regulation 2037/2000 Fluorinated Greenhouse Gases Regulation 842/2006 Energy Legislations Energy efficiency requirements for ballasts for fluorescent lighting - Directive 2000/55/EC and Regulation 245/2009 of the European Parliament and of the Council Safety Legislations Entire product Machinery Directive 95/16/EC General Product Safety Directive 2001/95/EC Low Voltage Equipment Directive 73/23/EEC Pressure equipment Directive (PED) 97/23/EC Most of the third country legislation identified is mandatory MEPS. The aim of MEPS is to remove the least efficient appliances from sale. A specific test standard for energy consumption measurement is often imposed in the MEPS. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 103

104 SERVICE CABINETS UK ECA incentive scheme for plug-in commercial service cabinets Eligibility criteria for the scheme are discussed in Performance criteria: Products must have an Energy Efficiency Index (EEI) that is less than, or equal to, the thresholds set out in Table 1-29 below, which depend on the type of cabinet. Table 1-29: EEI performance thresholds for commercial service cabinets 97 Where: EEI is defined as the TEC of the product over a 48 hour test period divided by the product s net volume (in m 3 ) Net volume equals: shelf (or drawer base) area x loading height TEC is as defined in BS EN 441-9:1995 Required test procedures: All cabinets must conform to the following temperature classifications (as defined in BS EN 441-6:1995) when tested to BS EN 441:1995/1996 in climate class IV (+30 C, 55% RH): For chilled cabinets: M1 (all measurement packs must be between 1 and +5 C). For frozen cabinets: L1 (the highest temperature of the warmest measurement pack must be less than or equal to 15 C and the lowest temperature of the warmest measurement pack must be less than or equal to 18 C). All cabinets must be tested according to the requirements for closed refrigerated cabinets contained in BS EN 441:1995/1996 with the following test conditions: Loading: as described in BS EN 441-5:1996. Cabinets with shelves, to be fitted with a minimum of one shelf per 300 mm of open height at equal distances apart. For upright units this equates to a minimum of 4 shelves and for under counter units to a minimum of two shelves. The lowest height shelf should be located at the lowest available height fitting. Temperature test: as described in BS EN 441-5:1996, specifically 3.6. Below is presented a figure showing the UK ECA VEPS and the performance of the vertical refrigerators and freezers that have been certified under the scheme. This shows a relatively wide spread of performance, indicating that there may be potential for even certified products to improve further. 97 ECA website, commercial service cabinets criteria: Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

105 TEC (kwh/day) Comparison of ETL list products' performance against the UK ECA performance criteria Net volume (litres) Single door (600 litres gross) refrigerator Single door (600 litres gross) freezers Double door (1300 litres gross) refrigerators Double door (1300 litres gross) freezers HT; Plug-in; Vertical; 1-door (UK ECA) HT; Plug-in; Vertical; 2-door (UK ECA) LT; Plug-in; Vertical; 1-door (UK ECA) LT; Plug-in; Vertical; 2-door (UK ECA) Figure 1-24 : UK ECA performance standards and ETL products US DOE MEPS The Energy Conservation Program for Commercial and Industrial Equipment final rule was published on January 9, 2009 by the US DOE. The energy conservation standards developed will apply to commercial refrigeration equipment manufactured on or after January 1 st, This rulemaking defines test procedures for measuring energy efficiency and related definitions for commercial refrigeration equipment including: Commercial ice-cream freezers Self-contained (i.e. plug-in) commercial refrigerators, freezers, and refrigerator-freezers without doors Remote condensing commercial refrigerators, freezers, and refrigeratorfreezers Scope: The scope of this rulemaking (Energy Conservation Standard Rulemaking) is defined by the three categories of products listed above. However, for remote cabinets, secondary coolant applications are not covered. This is consistent with the ANSI/AHRI 1200 standard which explicitly excludes secondary coolant applications. Requirements: The test procedure under consideration is the Air-Conditioning, Heating and Refrigeration Institute (AHRI) Standard 1200:2008, Performance Rating of Commercial Refrigerated Display Merchandisers and Storage cabinets (see ). ANSI/ARI Standard 1200 contains rating temperature specifications of 38 F (±2 F) for commercial refrigerators and refrigerator compartments, and 0 F (±2 F) for commercial freezers and freezer compartments. In the test procedure final rule, DOE also adopted a -15 F (±2 F) rating temperature for commercial icecream freezers. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 105

106 Table 1-30 presents MEPS for closed solid door remote condensing commercial refrigerators and commercial freezers and plug-in and remote Ice-cream freezers. Table 1-30: Maximum daily energy consumption Equipment category Equipment family Rating temperature ( F) Operating temperature ( F) Maximum daily energy consumption (kwh/day) Remote Condensing Commercial Refrigerators and Commercial Freezers. Vertical Closed Solid (service cabinet) Horizontal Closed Solid (service cabinet) V < V V < V Remote Commercial Icecream Freezers Plug-in Commercial Icecream Freezers Vertical Closed Solid V Horizontal Closed Solid V Vertical Closed Solid V Horizontal Closed Solid V US CEC MEPS It is interesting to note that although these MEPS cover plug-in (self-contained) solid-door ice-cream temperature products, they do not include refrigerators and freezers (HT and LT), while most stakeholders stated that the proportion of remote service cabinets is very low. This gap may be due to the original scope defined for the MEPS, perhaps focused on display cabinets which frequently rely on remote condensing. The US CEC adopted the California Appliance Efficiency Regulation, which became effective December 29, It was reviewed on 2009 and the document CEC was produced. Scope: The California Appliance Efficiency Regulation 98 includes energy efficiency levels for the following types of new appliances (within the scope of ENTR Lot 1): automatic commercial ice-makers, refrigerators and freezers with doors (i.e. service cabinets), walk-in refrigerators and freezers, and water dispensers. The Regulation excludes certain refrigeration appliances with a volume exceeding 85 ft 3 (2.4 m 3 ) and automatic commercial ice-makers with a harvest rate lower than 50 lbs/24 hours or greater than 2500 lbs/24 hours. Requirements: Volume shall be measured using ANSI/AHAM HRF Energy consumption shall be measured using 10 CFR Section (2008). In the case of service cabinets this regulation establishes maximum energy consumption in kwh, as a function of the volume in ft 3. The minimum standards described below apply to reach-in, pass-through, roll-in and roll-through product types. 98 California Energy Commission: Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

107 Table 1-31: Maximum daily energy consumption for solid-door service cabinets Appliance according to function Maximum daily energy consumption (kwh/day) Refrigeration 0.10 V Freezer 0.40 x V Refrigerator-freezer The greater of 0.27 x AV 0.71 or 0.70 Refrigerator-freezers that have an adjusted volume (AV) of less than 5.19 ft V: Volume (ft 3 ) AV: adjusted total volume, ft 3, as determined in 10 CFR, part 430, appendices A1 and B1 of subpart B (2008), which is: [1.63 x freezer volume (ft 3 )] + refrigerator volume (ft 3 ) for refrigerator-freezer Canada CAN/CSA-C Energy performance standard for food service refrigerators and freezers This standard applies to self-contained (i.e. plug-in) commercial refrigerators, refrigerator-freezers, and freezer cabinets that are intended for storage or holding food products and other perishable merchandise, except for cold rooms (walk-in coolers). The compliance date of this regulation started on April 1, 2007, with updated levels in January 2008 and the addition of remote products to the standard in January 2010 (adopting the US DOE standards). The test procedure under consideration is the Air-Conditioning, Heating and Refrigeration Institute (AHRI) Standard 1200:2008 in order to harmonise with the US DOE methodology. This regulation sets maximum daily electricity consumption figures (see Table 1-32). Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 107

108 Table 1-32: Canadian energy efficiency regulation on commercial refrigerated cabinets 99 Type Maximum E daily (kwh/day) Commercial refrigerator type Type April 1, December 31, 2007 on or after January 1, 2008 on or after January 1, 2010 Self-contained commercial refrigerators Self-contained commercial freezers opaque doors or drawers transparent doors V V N/A V V N/A other* N/A N/A N/A opaque doors V < N/A V V V N/A transparent doors V V N/A other* N/A N/A N/A Self-contained commercial opaque doors AV AV N/A refrigeratorfreezers other* N/A N/A N/A Remote commercial Any N/A N/A V refrigerators Remote Vertical N/A N/A V commercial freezers Horizontal N/A N/A V * Product has no energy efficiency performance requirements but must meet all other regulatory requirements Australia/New Zealand refrigerated display cabinets MEPS Since October 1, 2004, refrigerated display cabinets (both remote and plug-in) manufactured in or imported into Australia must comply with MEPS requirements. These are set out in AS Refrigerated display cabinets - Minimum energy performance standard (MEPS) requirements. Scope: The scope of commercial refrigeration MEPS includes both remote and plug-in refrigerated display cabinets primarily used in commercial applications for the storage of frozen and unfrozen food. It does not cover commercial refrigeration technologies or applications such as walk-in storage and freezer rooms, ice making and ice storage equipment, refrigerated vending machines, cold water dispensers and processing industries, such as abattoirs and dairies. Requirements: The MEPS for commercial refrigeration are set out in AS as TEC per Total Display Area (TEC/TDA) in kwh/day/m² for various unit 99 AV means the adjusted volume of the product in litres calculated as follows: AV = the refrigerator volume in litres H the freezer volume in litres. Products projected to be covered under ENTR Lot 1 are highlighted in grey Edaily means the daily energy consumption of the product expressed in kwh per day. V means the volume in litres of the refrigerated compartment. Use AHAM standard ANSI/AHAM HRF entitled Energy Performance and Capacity of Household Refrigerators, Refrigerator-Freezers and Freezers to calculate refrigerator or freezer compartment volumes. 108 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

109 types. Although service cabinets are not explicitly excluded from the scope of AS , the MEPS can not apply as no TDA can be defined for service cabinets US Energy Star voluntary programme for commercial solid door refrigerators and freezers This programme refers to the ASHRAE Standard , Method of Testing Commercial Refrigerators and Freezers, and defines energy efficiency requirements for service cabinets. It covers only the plug-in refrigerated cabinets with solid doors (chilled and frozen). Box 1-6 presents Energy Star program qualifying products, specifications and test requirements for commercial solid door refrigerators and freezers: Box 1-6: Energy Star Program for commercial solid door refrigerators and freezers 100 This programme states that labelled products are more energy efficient because they are designed with components such as ECM evaporator and condenser fan motors, hot gas anti-sweat heaters, or high-efficiency compressors to reduce energy consumption and utility bills. Compared to standard US models, Energy 100 Energy Star, see: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 109

110 Star labelled commercial refrigerators and freezers can lead to energy savings of as much as 35% (with a 1.3 year payback in the US) 101. The US experience also shows that companies offering Energy Star refrigerated display cabinets make up over 90% of the market and about products qualify in this range of products US CEE Commercial Kitchens Initiative This CEE initiative specifies voluntary minimum performance standards that take the previous US Energy Star standards further for the categories shown in the table below. Table 1-33: US CEE Commercial Kitchens Initiative VEPS US AHRI certification programme for commercial refrigerated display merchandisers and storage cabinets Scope: Commercial Refrigerated Display Merchandisers and Storage Cabinets. Covered products described in the Scope of Program (plug-in and remote) document and that are offered for sale in the US, Canada and Mexico. Remote models are not included in the scope of this certification programme at this time. Reference standard: ANSI/AHRI Standard 1200:2008 Certified Ratings: The following certification programme ratings are verified by test: TDEC (kwh per day) Refrigerated Volume (ft 3 [m 3 ]) TDA (ft 2 [m 2 ]) For plug-in cabinets, ARI evaluates the performance of the cabinet by calculating the daily energy consumption as a function of the refrigerated volume for products with doors and as a function of the TDA for open cabinets because these respective parameters (i.e. volume and TDA) appear to be the most representative of the energy consumption of these products. Minimum performance criteria to attain certification are not published. 101 Source: Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

111 BLAST CABINETS No MEPS, voluntary standards or incentive schemes specific to blast cabinets were identified. There are however relevant health and safety regulations, as discussed in FR commercial food preparation hygiene requirements law of 29/09/1997 Relevance: blast cabinets, service cabinets The French law of 29/09/1997 established that all foodstuff elaborated in restaurants should reach temperatures from +63 C to below +10 C within a maximum of 3 hours after preparation. This law does not expressly recommend blast cabinets, but in practice it encourages their use UK Department of Health Guidelines Relevance: blast cabinets In the Guidelines for Cook Chill and Cook Freeze Catering Systems (1989), it is expressed that blast chillers should cool down the temperature of foodstuffs from +70 C to +3 C in 90 minutes in order to be considered as safe for storage Austrian Hygiene Certificate Guideline Relevance: blast cabinets According to this hygiene guideline for large-scale catering establishments, such as those within the health service, and comparable equipment for foodstuff (Gutachten des Ständigen Hygiene-Ausschusses Hygiene-leitlinie für Grossküchen, Küchen des Gesundheitswesens, und vergleichbare Einrichtungen der Gemeinschaftsverpflegung), foodstuff prepared in commercial and health establishment kitchens that is not meant to be consumed immediately after cooking should be cooled from +75 C to +10 C within an hour. Afterwards, the foodstuff must be kept in service cabinets WALK-IN COLD ROOMS US minimum requirements for walk-in cold rooms and walk-in freezers 102 The US CEC proposed the introduction of energy-related design standards for walk-in cold rooms manufactured before January 1 st 2009, as described below. 102 www1.eere.energy.gov/buildings/appliance_standards/commercial/wicf_faqs.html#doors4 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 111

112 Table 1-34: US CEC design standards for walk-in cold rooms Walk-in coolers and walk-in freezers manufactured in the US on or after January 1, 2009 should: have automatic door closers that firmly close all appliances that have been closed within 2.54cm of full closure, except for doors wider than 1.14m and taller than 2.14m; have strip doors, spring hinged doors, or another method of minimising infiltration when doors are open; contain wall, ceiling, and door insulation of at least R (U value of 0.23) for coolers and R-32 (U value of 0.18) for freezers, except that this subparagraph shall not apply to glazed portions of doors nor to structural members; contain floor insulation of at least R-28 (U value 0.20) for freezers; for evaporator fan motors of under one horsepower and less than 460 volts, use: o o electronically commutated motors (brushless direct current motors); or 3-phase motors; for condenser fan motors of under one horsepower, use: o o o electronically commutated motors; permanent split capacitor-type motors; or 3-phase motors; and for all interior lights, use light sources with an efficacy of 40 lumens per watt (LPW) or more, including ballast losses (if any), except that light sources with an efficacy of 40 LPW or less, including ballast losses (if any), may be used in conjunction with a timer or device that turns off 103 R value described in ; 1 h.ft². F/Btu = K.m²/W 112 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

113 the lights within 15 minutes of when the walk-in cooler or walk-in freezer is not occupied by people. Walk-in coolers equipped with transparent reach-in doors and walk-in freezers equipped with transparent reach-in doors and manufactured on or after January 1, 2009 shall also meet the following design standards: transparent reach-in doors for walk-in freezers and windows in walk-in freezer doors shall be of triple-pane glass with either heat-reflective treated glass or gas fill; transparent reach-in doors for walk-in coolers and windows in walk-in cooler doors shall be either: 1. double-pane glass with heat-reflective treated glass and gas fill; or 2. triple-pane glass with either heat-reflective treated glass or gas fill; 3. if the appliance has an antisweat heater; without antisweat heat controls, the appliance shall have a total door rail, glass and frame heater power draw of not more than 7.1 watts per square foot (W/ft²) (0.66 W/m 2 ) 104 of door opening (for freezers) and 3.0 W/ft² (0.28 W/m 2 ) of door opening (for coolers); with antisweat heat controls, and where the total door rail, glass and frame heater power draw is more than 7.1 W/ft² (0.66 W/m 2 ) of door opening (for freezers) and 3.0 W/ft² (0.28 W/m 2 ) of door opening (for coolers), the antisweat heat controls shall reduce the energy use of the antisweat heater in a quantity corresponding to the relative humidity in the air outside the door or to the condensation on the inner glass pane. Testing requirements: Please see US DOE proposed testing procedure for walk-in coolers and freezers 105 The US DOE has been developing a proposal for evaluation methods for walk-in cold rooms. Please see UK ECA incentive scheme for cellar cooling equipment 106 Cellar cooling equipment covers products that are specifically designed to maintain, by means of a refrigeration system, an indoor environment at a condition suitable for the storage of chilled beverages below +12 C. The scheme covers three categories of cellar cooling equipment: Packaged units where all components mounted on one base for "through the wall installation. Split systems with the equipment supplied in two parts (evaporator and condensing unit) to be connected on installation. Remote systems with equipment supplied in three parts (evaporator, compressor/receiver, and condenser) to be connected on installation ft 2 = m www1.eere.energy.gov/buildings/appliance_standards/commercial/wicf.html Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 113

114 To be eligible, products must: Have a cooling capacity of between 2 kw and 12 kw at the standard rating conditions for ambient air temperature of 32 C and a cellar air temperature of +10 C. Either be a single packaged unit, or consist of two or three factory-built sub-assemblies that are designed to be connected together during installation. Conform with the requirements of EU Pressure Equipment Directive PED 97/23/EC. Products must have a coefficient of performance (COP) equal to or greater than the figures shown below. Table 1-35: Performance requirements for ECA approval of cellar cooling equipment Testing is carried out in accordance with PAS 57:2003 with some amendments designed to reduce variability of results of the test methodology PQS Quality Assurance protocol E01/CR/FR-VP2 The document, published as guidance from the World Health Organisation, sets out a Quality Assurance (QA) protocol for the installation of cold rooms and freezer rooms. Combination cold and/or freezer rooms are required to comply with all specifications for both cold room and freezer rooms. It is stated that the assessment should be conducted by the customer, or their designated QA assessor. The interesting aspect of this for walk-in cold rooms is the Holdover test, a simple test procedure for the insulated enclosure whereby the electricity supply is cut off and the period required for the internal temperature to rise to +10 C (for cold rooms, or -10 C for freezer rooms) from normal operating temperature is recorded (BS EN :1991 is referenced within the documentation see ). The door must remain closed throughout the test. External ambient air temperature is also recorded throughout the test period. Compliance is proven if the time period is equal to, or greater than, 8 hours. Follow-up documentation and questionnaires are proposed to ensure evidence of conformity, and provide the customer with explanatory details of the design and questions to provoke good user practice. The cost of the Holdover test is approximately Source: ECA Scheme 108 Source : GR Scott 114 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

115 ATP agreement on the international carriage The agreement details the following aspects of interest: Minimum requirements K coefficient values for the insulated enclosure: The K coefficient of equipment of classes B, C, E and F shall in every case be equal to or less than 0.40 W/m 2.K (classes that are required to go down to (or below) -10 C), and the other classes equal or lower to 0.70 W/m 2.K. In the case of separate testing of insulated enclosure and refrigeration system) a minimum required cooling capacity factor for the refrigeration system: if the refrigerating system with all its accessories has undergone separate test to determine its effective refrigerating capacity at the prescribed reference temperatures, it will be acceptable if the effective refrigerating capacity of the system in continuous operation exceeds the heat loss through the walls for enclosure tested under the class considered, multiplied by the factor System of certification that incorporates type approval for similar equipment (differentiating parameters that would not be permitted within this approval are defined). Requirements for product marking. Requirements for product test reports. The agreement states that checks for conformity with the standards prescribed shall be made: (a) before equipment enters into service; (b) periodically, at least once every six years; (c) whenever required by the competent authority. Except in the cases provided for in appendix 2, sections 5 and 6 of the agreement, the checks shall be made at a testing station designated or approved by the competent authority of the country in which the equipment is registered or recorded, unless, in the case of the check referred to in (a) above, a check has already been made on the equipment itself or on its prototype in a testing station designated or approved by the competent authority of the country in which the equipment was manufactured. A certificate of compliance with the standards shall be issued by the competent authority of the country in which the equipment is to be registered. This documentation, or the required manufacturer s plate, can be used by competent authorities for identification during inspection. Product ranges can be Type Approved to the required standards, after testing of one unit, after which Type Approval certification lasts for 6 years. The competent authority shall take steps to verify that production of other units is in conformity with the approved type. For this purpose it may check by testing sample units drawn at random from the production series. After 6 years, it is possible to renew the certification for 3 year periods by having an in-service K coefficient test at an approved ATP Designated Station authorised by any country that is a signatory to the agreement. If, in the course of the six-year period, the production series exceeds 100 units, the competent authority shall determine the percentage of units to be tested. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 115

116 If a vehicle fitted with equipment does not have an ATP certificate, and no Type Approvals have been issued, then the only option is to obtain a certificate by having a one off test at an approved test centre or at the owner s site. A unit shall not be regarded as being of the same type as the unit tested unless it satisfies the following minimum conditions: (i) If it is insulated equipment, the construction shall be comparable and, in particular, the insulating material and the method of insulation shall be identical: (ii)... the thickness of the insulating material shall be not less than that of the reference equipment; the interior fittings shall be identical or simplified; the number of doors and the number of hatches or other openings shall be the same or less; and the inside surface area of the body shall not be as much as 20% greater or smaller. (iii) If it is mechanically refrigerated equipment, in which case the reference equipment shall be either:... (a) mechanically refrigerated equipment; the conditions set out in (i) above shall be satisfied; and the effective refrigerating capacity of the mechanical refrigeration appliance per unit of inside surface area, under the same temperature conditions, shall be greater or equal; or (b) insulated equipment to which it is intended to have fitted, at a later date, a mechanical refrigeration unit and which is complete in every detail but with the refrigeration unit removed and the aperture filled, during the measurement of the K coefficient, with close fitting panels of the same overall thickness and type of insulation as is fitted to the front wall. In which case: the conditions set out in (i) above shall be satisfied; and the effective refrigerating capacity of the mechanical refrigeration unit fitted to insulated reference equipment shall be as defined. For further explanations of the agreement, including definitions and test procedures, please see Annex 1-1, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

117 PROCESS CHILLERS EU EUROVENT certification programme for liquid chilling packages A EUROVENT certification scheme for liquid chilling packages exists. Scope: this certification scheme applies to standard chillers used for air conditioning and for refrigeration and covers three applications: air conditioning, with leaving chilled water temperature between +2 C and +15 C medium brine, with leaving brine temperature between +3 C and -12 C low brine, with leaving brine temperature between -8 C and -25 CA special application for heating and cooling floors is also included. They may operate with any type of compressor, but only electrically driven chillers are included. All refrigerants are considered. Chillers may be air-cooled, water cooled or evaporative cooled and with remote condensers. Reverse cycle chillers shall be certified in cooling and in heating mode. The following units are excluded from the programme: chillers powered by other than electric motor drives, free cooling ratings, heat recovery and no reverse cycle heat pumps and 60 Hz units. Requirements: Cooling capacity standard ratings are established at the Standard Rating Conditions and verified by tests conducted in accordance with EN Table 1-36 presents the capacity test Standard Rating Conditions that apply for each application. Table 1-36: Capacity test Standard Rating Conditions 109 Temperatures Cooling Heating Application Code Evaporator Condenser Evaporator Condenser LCP/A../AC Air / Water +12 to +7 35a 40/45 7(6) LCP/W../AC Water / Water +12 to +7 30/35 40/45 10/b LCP/W../AC-MB Air conditioning Water / Brine +12 to +7 30/35 40/45 0/-3 LCP/T../AC without flasheconomiser LCP/T../AC with flasheconomiser +12 to to c 45d LCP/A../MB Air / Water -5 to 0 35a 40/45 7(6) LCP/W../MB Brine / Brine -5 to 0 30/35 40/45 10/b Medium Brine or Brine / Water LCP / T../MB without flasheconomiser LCP/T../MB -5 to 0-5 to b 45d EUROVENT website: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 117

118 Low Brine Cool-heating Floor with flasheconomiser LCP/A../LB Air / Water LCP/W../LB Brine / Brine or Brine / Water LCP/T../LB without flasheconomiser LCP/T../LB with flasheconomiser LCP/A../CHF Air / Water LCP/W../CHF Water / Water LCP/W../CHF-MB Brine / Brine or Water / Brine Temperatures Cooling Heating -15 to a 40/45 7(6) -15 to /35 40/45 10/b -15 to b to d to a 30/35 7(6) +18 to /35 30/35 10/b +18 to /35 30/35 0/-3 a = Measurement with the same water flow as in cooling mode, b = Dry bulb; c = The temperature corresponds to compressor discharge pressure (bubble point) liquid at expansion valve; d = The temperature corresponds to compressor discharge pressure The following characteristics of Liquid Chilling Packages are verified by tests at Standard Rating Conditions and at one of the Application Rating Conditions selected by Eurovent: cooling capacity energy efficiency ratio (EER) European Seasonal Energy Efficiency Ratio (ESEER 110 ) water pressure drop at evaporator in cooling mode (units without pump) available pressure at evaporator in cooling mode (units with pump) water pressure drop at condenser in cooling mode A-weighted sound power level for air cooled chillers heating capacity for reverse cycle units coefficient of performance water pressure drop at evaporator in heating mode (units without pump) available pressure at evaporator in heating mode (units with pump) water pressure drop at condenser in heating mode Energy Efficiency Classification of equipment: The purpose of Eurovent Energy Efficiency Classes is to simplify the selection of the best units for each type of chillers. 110 The European Seasonal Energy Efficiency Ratio is a weighed formula taking into account the variation of EER with the load rate and the variation of air or water inlet condenser temperature. ESEER is calculated as follows: ESEER = 0.03.EER100% EER75% EER50% EER25% 118 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

119 The classification (see Table 1-37) is entirely voluntary and is based on existing chillers presented to certification. It is not related to any European Directive. The energy efficiency of chillers is designated by Eurovent Class A or Eurovent Class B in catalogues. Table 1-37: Energy efficiency classification in cooling mode 111 Part load certification: Chillers usually operate at full load only during a limited period of time during a year. Therefore, the part load performance is closer to reality and Eurovent decided to certify, together with full load efficiency, an average annual part load efficiency of chillers. A study 112 partly funded by the European Commission through the SAVE Programme was performed and an index called ESEER Seasonal energy efficiency ratio has been defined. This index is similar to the IPLV (Integrated Part Load Value) used by ARI in the US and takes into account several parameters in order to establish an average use of chillers throughout Europe: weather data, building load characteristics, operational hours etc. Therefore, the ESEER is a realistic tool, much better than full load EER, to be used to compare average efficiency of two chillers. However, it must be kept in mind that ESEER cannot be used to calculate exact energy consumption for a particular use in a particular geographic position. Neither ESEER nor IPLV give an indication of energy use in an industrial application, but are instead relevant to air conditioning applications. In order to compute ESEER the three part load EER for 25%, 50% and 75% load are combined with full load EER. This global single figure is published in the Eurovent Directory of certified products together with cooling capacity and power input for standard conditions at full load. The operating temperatures and average weighting coefficients for Europe are given in Table EUROVENT website: Energy Efficiency and Certification of Central Air Conditioners (EECCAC), Save Programme: Project /P/ , co-ordinator: ARMINES, April 2003 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 119

120 Table 1-38: Operative ESEER temperatures and coefficients for air cooled and water cooled chillers in Europe 113 Stakeholders mentioned that the ESEER is soon to be replaced by SEER (as defined in pren 14825:2009) UK ECA incentive scheme for packaged chillers Eligibility Criteria: To be eligible, products must: Incorporate an electrically powered compressor (or compressors). Be one of the 16 specific categories of packaged chillers covered by the ECA Scheme as detailed in table below, which are classified according to: o o o o Refrigeration capacity (in kw). Whether the product is air-cooled or water-cooled. Whether the product uses an integral or remote condenser. The heat transfer medium used (water or brine). Be subject to quality assurance procedures that ensure consistency of performance between one production item and any other. Be CE Marked. 113 EUROVENT Website: Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

121 Table 1-39: Performance thresholds for packaged chillers 114 Where: EER = net cooling capacity (kw) / effective power input (kw) in cooling mode. COP = net heating capacity (kw) / effective power input (kw) in heating mode. The refrigeration capacity (kw) is determined in accordance with the procedures and rating conditions in BS EN 14511:2004 or 2007 Air conditioners, liquid chilling packages and heat pumps with electrically driven compressors for space heating and cooling. Required test procedures: All products must be tested in accordance with the procedures and standard rating conditions laid down in BS EN 14511:2004 or A detailed test report must be prepared for each individual product. 114 ECA Website, packaged chillers criteria: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 121

122 US ASHRAE Relevance: Industrial process chillers The ASHRAE Standard Energy standards for buildings except low-rise residential buildings provides minimum energy-efficiency requirements for the design and construction of new buildings and their systems, new portions of buildings and new systems in existing buildings. It includes Minimum Efficiency Requirements for water chilling packages with reference to AHRI 550/590 test method for electrically operated water chilling packages, and ANSI/AHRI 560 test method for absorption water chilling packages. The recommended energy performance levels from this standard are as follows: Table 1-40: Performance levels for chillers according to ASHRAE table C Chiller Capacity (RT refrigeration tonne) COP* IPLV* Air cooled electrical All Air cooled w/o condenser All Water cooled Reciprocating All < 150 RT (530 kw) Water cool screw rotary 150 RT and < 300 RT and scroll (530kW 1,060kW) RT (1,060kW) < 150 RT (530 kw) Water cool Centrifugal 150 RT and < 300 RT (530kW 1,060kW) RT (1,060kW) Air cooled absorption single effect All 0.60 Water cooled absorption All 0.7 Absorption double effect indirect fired All Absorption double effect direct fired All *COP Coefficient of Performance *IPLV Integrated Part Load Value CAN CSA-C performance standard for packaged water chillers The CAN/CSA-C Performance Standard for Rating Packaged Water Chillers applies to factory-designed and prefabricated water-cooled absorption chiller/heater units, single-effect indirect-fired by steam or hot water, and doubleeffect, both indirect-fired by steam or hot water and direct-fired by oil, natural gas, or LP gas; water is the refrigerant and lithium bromide is the absorbent. This standard does not apply to absorption chiller/heater units with air-cooled condensers, nor does it apply to applications employing heat pumping or exhaust gas firing. 122 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

123 Table 1-41: Minimum Energy Efficiency Requirements for Packaged water chillers 115 Type Capacity range, kw (tons) COP 116 IPLV 117 air-cooled with condenser Vapour compression < 528 (150) (150) air-cooled without condenser all water-cooled, reciprocating all water-cooled, rotary screw, scroll water-cooled, centrifugal < 528 (150) (150) and 1,055 (300) >1,055 (300) < 528 (150) (150) and 1,055 (300) Absorption > 1,055 (300) single-effect absorption, air-cooled all 0.60 N/A single-effect absorption, water-cooled all 0.70 N/A double-effect absorption, indirect-fired all double-effect absorption, direct-fired all Australia/New Zealand water chillers MEPS The MEPS covered by AS/NZS :2008 concerns water chillers with a capacity higher than 350kW. Table 1-42: Minimum Energy Efficiency Requirements for Packaged water chillers 118 Capacity range, kwh Minimum COP Minimum IPLV Air cooled Water cooled Air cooled Water cooled <350 N/A N/A N/A N/A > Canadian Office of Energy Efficiency: oee.nrcanrncan.gc.ca/regulations/packaged_water_chillers.cfm?attr=8 116 COP: Coefficient Of Performance is the ratio of the cooling capacity in watts [W] to the power input value in watts [W] at any given set of Rating Conditions expressed in watts/watt [W/W] 117 IPLV: Integrated Part Load Value is a single number part-load efficiency figure of merit calculated per the methods described in 5.3 of ARI 560 relative to Absorption Water Chilling And Water Heating Packages Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 123

124 REMOTE CONDENSING UNITS UK ECA incentive scheme for air-cooled condensing units Eligibility Criteria: To be eligible, products must: Operate with one or more identified standard refrigerants, Be a factory assembled unit that incorporates the following components (at least): o o o air-cooled refrigerant condenser, one or more electrical compressors a control systems for the compressor(s) and cooling fan(s) Conform to requirements to respect design, manufacture and testing procedures. Have a COP greater than the values shown in Table Temperature category Table 1-43: Performance thresholds for air-condensing units 119 Evaporating temperature (Dew point) ( C) Ambient (condenser airon) temperature ( C) Compressor suction gas temperature ( C) COP threshold HT units MT units LT units Where: COP = net heating capacity (kw) / effective power input (kw) in heating mode. The refrigeration capacity (kw) is determined in accordance with the procedures and rating conditions in BS EN 14511:2004 or 2007 Air conditioners, liquid chilling packages and heat pumps with electrically driven compressors for space heating and cooling. Required test procedures: the performance can be tested by either of the two following methods: Method A: COP at relevant UK rating point (see Table 1-43) must be calculated with the method used to generate its published performance over the standard range of air temperature and evaporating temperature conditions. The accuracy must be confirmed in the following way: performance should be determined at three test conditions within +/-+1 C of the temperatures in Table 1-43; the level of uncertainty (at 95% confidence) in the calculated values of COP must be determined using statistical methods. 119 ECA website, packaged chillers criteria: Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

125 The COP must exceed the threshold proposed in Table 1-43 by at least the level of uncertainty in the calculations. The test report must include: Method B: details of calculations method used to determine COP, a copy of the published performance data for the product, manufacturer s design data for the product and key components (including refrigerant, condenser fan motor type, and condenser), refrigerating capacity and COP of the compressor, where applicable, evidence of independent verification of the compressor, copy of the compressor s performance data by the manufacturer, test data from the product operating at full load: o o o o compressor s inlet and outlet condensing and evaporating pressures and dew temperatures, superheat and sub-cooling at the compressor s inlet and the unit s outlet; condenser air inlet temperature, compressor input power in kw (where compressors are not listed on the Energy Technology Product list, or their performance independently verified) When using this method, the performance of the product must be demonstrated following the procedure from BS EN :2007 (see ). To obtain the refrigerant properties, one of the following standards must be used: The US National Institute of Standards and Technology (NIST) Standard reference database 23 thermodynamics and transport properties of refrigerants and refrigerant mixtures database : 6.0 or later. The ASERCOM properties database as defined in the ASERCOM Compressor certification scheme, which is based closely on the NIST database. Data for a suction gas temperature of +20 C may be obtained by the thermodynamic translation of data physically tested at 10K superheat 120. This is only applicable for high temperature only. 120 Superheating refers to the process of heating a substance over its boiling point. This is reached under specific pressure conditions. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 125

126 The report shall include a statement of achieve performance according to Table 1-43, and data on refrigerating capacity and COP at +32 C as specified in EN 13215: EU ENVIRONMENTAL LEGISLATIONS The following European environmental legislation applies at the product level European Directive 2002/96/EC on Waste Electrical and Electronic Equipment (WEEE) The WEEE Directive, effective 13 August 2005, requires separate collection, treatment and recovery of electrical and electronic waste. The purpose of the Directive is as a first priority, the prevention of waste electrical and electronic equipment (WEEE), and in addition, the reuse, recycling and other forms of recovery of such wastes so as to reduce the disposal of waste. Scope: The Directive applies to electrical and electronic equipment 121 falling under the categories set out in Annex IA of the Directive. According to the list of products provided in Annex IB, large cooling appliances, refrigerators, freezers and other large appliances used for refrigeration, conservation and storage of food fall under the category 1 Large household appliances of Annex IA. Targets for category 1 are set to: 75% of reuse and recycling of component, material and substance by an average weight per appliance 80% of recovery (reuse and recycling + energy recovery) by an average weight per appliance Environmental aspects of the products that can be impacted by the standard: End of life, material content. In December 2008, the EU Commission published a proposal for revision of the WEEE Directive. The main objectives of this revision are to set new collection and treatment targets and to clarify the scope and definitions of current legislation European Directive 2002/95/EC on the Restriction of the use of certain Hazardous Substances in electrical and electronic equipment (RoHS) This RoHS Directive requires the substitution of various heavy metals (lead, mercury, cadmium, and hexavalent chromium) and brominated flame retardants (polybrominated biphenyls (PBB) and polybrominated diphenyl ethers (PBDE)) in new electrical and electronic equipment put on the market from 1 July Scope: The Directive applies to the categories of electrical and electronic equipment that are covered by the WEEE directive except medical devices and 121 EEE: equipment which is dependent on electric currents or electromagnetic fields in order to work properly and equipment for the generation, transfer and measurement of such currents and fields designed for use with a voltage rating not exceeding Volt for alternating current and Volt for direct current 126 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

127 monitoring and control instruments. This Directive covers assemblies or subassemblies of products. According to the list of products provided in Annex IB, large cooling appliances, refrigerators, freezers and other large appliances used for refrigeration, conservation and storage of food fall under the category 1 Large household appliances of Annex IA. Environmental aspects of the products that can be impacted by the standard: Material content. The RoHS revision published in December 2008, foresees incorporation of categories 8 and 9 of Annex IA (Medical products and monitoring and control instruments) into RoHS. The proposal calls for most medical products to be compliant by January 1, 2014, in vitro medical devices to be compliant by January 1, 2016, and industrial monitoring and control instruments by January 1, LEGISLATION RELATED TO REFRIGERANT FLUIDS European Regulation N 2037/2000 on Ozone Depleting Substances (ODS) Following the Montreal Protocol, the EU implemented Regulation EC No. 2037/2000 on substances that deplete the ozone layer. It specifies an accelerated HCFC (hydrochlorofluorocarbon) phase out schedule, compulsory recovery of CFCs (chlorofluorocarbons) and HCFCs or ban of their use, and leak control. The European schedule for the phase out of ozone depleting refrigerants is stricter than the one established by the Montreal Protocol (and chosen by the US). This triggered a transition in the choice of refrigerants used in the commercial refrigeration industry. From 2000 to 2002, the use of CFCs, the production of CFCs and the production of equipment using such refrigerant were banned. Since January 2001, the use of HCFCs in new systems in Europe for all types of refrigeration equipment has been forbidden. Concerning HCFC production, the regulation adopted the following provisions for actors selling these refrigerants, and for their use: 01/01/2008: Reduction of sales by 85% with respect to 2001, lowering of production by 65% with respect to 1997; 01/01/2010: Prohibiting of sales of virgin HCFCs; 01/01/2010: Prohibiting of the use of virgin HCFCs in the maintenance and servicing of all equipment; 01/01/2014: Lowering of production by 80% with respect to 1997; 01/01/2015: Prohibiting of the use of recycled HCFCs in the maintenance and servicing of all equipment; 01/01/2020: Lowering of production by 85% with respect to 1997; 01/01/2025: Prohibiting of production. Recycled or reclaimed HCFCs may only be used for the servicing and maintenance of refrigeration equipment until 2015 (as already foreseen in Regulation EC N 2037/2000), only if they are recycled by the company operating the equipment Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 127

128 or carrying out the servicing or maintenance. Furthermore, the revision introduces amendments to the current legislation to facilitate the task of enforcing and preventing the illegal trade or use of ODS in the EU. It also tightens current provisions on the recovery and destruction of ODS contained in products and equipment the so-called ODS banks. The new provisions include a list of new substances in the regulation for the first time and for which the reporting of volumes produced and imported is required. The revision also bans the use of methyl bromide for quarantine and pre-shipment as of March European Regulation N 842/2006 on certain fluorinated greenhouse gases The European Regulation N 842/2006 regulation entered into force on 4 July 2006 and applies from 4 July The objective of this Regulation is to contain, prevent and thereby reduce emissions of the fluorinated greenhouse gases covered by the Kyoto Protocol. Scope: It applies to the fluorinated greenhouse gases listed in Annex I of the regulation. This Regulation addresses: the containment, the use, the recovery and the destruction of the fluorinated greenhouse gases listed in Annex I of the regulation the labelling and disposal of certain products and equipment containing those gases; the reporting of information on those gases the control of uses referred to in Article 8 of the regulation the prohibitions with respect to placing on the market of the products and equipment referred to in Article 9 and Annex II of the regulation the training and certification of personnel and companies involved in certain activities provided for by this regulation According to Article 3, the following test intervals are given. Table 1-44: Test intervals for refrigeration systems with varying refrigerant charges Test interval Quantity of fluorinated greenhouse gases Every 12 months 3 kg 6 kg for labelled, hermetically sealed systems 30 kg for systems with automatic leakage detection system Every 6 months 30 kg 300 kg for systems with leakage detection system Every 3 months 300 kg and an obligation to install a leakage detection system After repair of a leak, the refrigerating systems shall be checked for leak tightness within one month to ensure that the repair was effective. Users, whose refrigerating systems have a refrigerant charge of more than 300 kg are required to install leakage detection systems. These leakage detection systems are checked at least once per year to ensure proper functioning. If a correctly functioning and suitable leakage detection system is available, the frequency of the above required control measures is halved. 128 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

129 The following table presents the schedule of prohibition of placing on the market of products and equipments containing fluorinated greenhouse gases listed in the Annex I of the regulation: Table 1-45: Schedule of prohibition of placing on the market of fluorinated greenhouse gases containing equipment Fluorinated greenhouse gases Products and equipment Date of prohibition fluorinated greenhouse gases non-refillable containers 4 July 2007 hydrofluorocarbons and perfluorocarbons non-confined direct-evaporation systems containing refrigerants 4 July 2007 perfluorocarbons fire protection systems and fire extinguishers 4 July 2007 fluorinated greenhouse gases windows for domestic use 4 July 2007 fluorinated greenhouse gases other windows 4 July 2008 fluorinated greenhouse gases Footwear 4 July 2006 fluorinated greenhouse gases Tires 4 July 2007 fluorinated greenhouse gases DK statutory order one component foams except when required to meet national safety standards 4 July 2008 Hydrofluorocarbons Novelty aerosols 4 July 2009 This Danish legislation bans the use of HFC in foams and refrigeration systems except with charges between 10 kg and 250 kg. This Order applies to HFCs, perfluorocarbons (PFC) and sulphurhexafluoride (SF 6 ) and sets a general ban on new products containing these substances from June There are some exemptions from this general ban. For instance, the ban on HFCs will come into force for cooling equipment with HFC charges > 10 kg from and the use of HFC for service purposes is exempted from the Order Austria Ordinance No 447/2002 Amended by Ordinance No 139/2007: The Ordinance bans the placing on the market and use of hydrofluorocarbons (HFCs), perfluorocarbons (PFCs) and sulphur hexafluoride (SF6) greenhouse gases in certain equipment, units and products, unless they are used for research, development and analytical purposes. Concerning stationary applications, the bans apply only to small plug-in units with a refrigerant charge of 150g or less and to stand alone equipment with a refrigerant charge of 20 kg or more Norway - Tax and refund scheme for imported HFCs This policy measure is a tax on imported HFCs and PFCs, which was introduced explicitly as a greenhouse gas reduction measure. The special tax (Regulations no of 11 December 2001) is set at Norwegian Kroner (approximately 24 ) per tonne of CO 2 - equivalents and applies to both imports as well as national production (although there is currently none) of HFC gases, whether in bulk or in products. The tax, which is collected by the Norwegian Ministry of Finance, makes 122 Danish Ministry of the Environment website: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 129

130 the import price of the refrigerant higher, leading to a more restricted use of the gas, and bringing alternatives within reach. The tax is coupled to a refund scheme. As a result the tax for R404a is currently at approximately 82 /kg and for R134a at 32 /kg. A refund of taxes on HFCs and PFCs (Regulations no of 30 June 2004) is paid to stimulate the safe removal and disposal of refuse gas. The refund is disbursed for the quantity of HFCs and PFCs that is delivered to an approved destruction facility for destruction. The refund rates equal the differentiated tax rates for the tax on HFCs and PFCs applicable at the time of delivery. The refund is administered by the Ministry of Environment s Pollution Control Authority (SFT) ENERGY-EFFICIENCY AND USE LEGISLATION This section presents the extent to which the components used in refrigerating equipment are covered by existing legislation, and in particular Ecodesign implementing measures. As a general guideline, energy efficiency related components of the products covered in the ENTR lot 1 study will be covered by the study as follows: If the component is placed separately on the market and then integrated in refrigerating equipment (e.g. a pump bought for a remote unit): o o If Ecodesign measures covering the component are in place it is then covered by the relevant Ecodesign measure If no specific Ecodesign measure is in place improvement solutions for this component will be investigated in the study If the component is bought on the OEM (Original Equipment Manufacturer) market and then integrated in a refrigerating equipment which is CEmarked: o o If relevant Ecodesign measures are in place, the Ecodesign measure on refrigerating equipment may require that components comply with them If no specific Ecodesign measure is in force or covers the given component (e.g. some motors used in refrigerating equipment do not fall into the scope of the dedicated Ecodesign measure), improvement solutions for this component will be investigated in the study EuP TREN Lot 13 Legislation related to household refrigerating appliances Ecodesign requirements for household refrigerating appliances have been developed in the framework of the Ecodesign Directive 2009/125/EC based on a preparatory study on domestic refrigerators and freezers (TREN Lot 13) 123. This Regulation establishes ecodesign requirements for the placing on the market of electric mains-operated household refrigerating appliances with a storage volume up to litres. 123 TREN Lot 13 Website: Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

131 Generic ecodesign requirements (see Annex II.1 of the Regulation) apply to wine storage appliances and household refrigerating appliances. Specific ecodesign requirement (see Annex II.2 of the Regulation) apply to household refrigerating appliances with a storage volume equal to or higher than 10 litres, and neither to wine storage appliances and nor to absorptiontype refrigerating appliances and other-type refrigerating appliances belonging to Categories 4 to 9. The requirements are presented in the table below. Table 1-46: Specific ecodesign requirements for household refrigerating appliances Appliance type Application date Energy Efficiency Index (EEI) 1 July 2010 EEI < 55 Compression-type refrigerating 1 July 2012 EEI < 44 appliances 1 July 2014 EEI < 42 Absorption-type and other-type refrigerating appliances 1 July 2010 EEI < July 2012 EEI < July 2015 EEI < 110 The Energy Efficiency Index of household refrigerating appliances is calculated in accordance with the procedure described in Annex IV of the Regulation EuP TREN Lot 11 Electric motors Ecodesign requirements for electric motors have been developed in the framework of the Ecodesign Directive 2009/125/EC based on the TREN Lot 11 preparatory study 124, covering: Electric motors 1-150kW Water pumps (in commercial buildings, drinking water pumping, food industry, agriculture) Circulators in buildings Ventilation fans (non-residential buildings) So far, ecodesign requirements have only been put in place for electric motors and circulators. Requirements for fans and water pumps are under development. Motors Minimum efficiency requirements have been established for electric motors in Commission Regulation (EC) No 640/2009 of 22 July 2009 implementing Directive 2005/32/EC of the European Parliament and of the Council with regard to ecodesign requirements for electric motors, including electric motors equipped with variable speed drives, and motors integrated into other products apart from motors completely integrated into a product (for example gear, pump, fan or compressor) of which the energy performance cannot be tested independently from the product. The motors falling under the scope of the Ecodesign requirements are electric single-speed, three-phase 50 Hz or 50/60 Hz, squirrel cage induction motor, from 0.75 to 175 kw that: have 2-6 poles; 124 TREN Lot 11 Website: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 131

132 have a rated voltage of UN up to 1000 V; have a rated output PN between 0.75 kw and 375 kw; and is rated on the basis of continuous duty operation. The EC ecodesign requirements for motors (nominal minimum efficiencies) are set out in Annex I of the draft commission regulation. The regulation is therefore not applicable to products or components covered in ENTR Lot 1, as motors are either small and single-phase (for use as fans) or integrated into hermetic compressors. Fans The possible ecodesign requirements for fans (minimum energy performance requirements) are set out in Annex I of the working document on possible ecodesign requirements for ventilation fans, and are proposed to cover fans from 125W to 500kW across the following types: Axial fan Centrifugal forward curved fan and centrifugal radial bladed fan Centrifugal backward curved fan without housing Centrifugal backward curved fan with housing Mixed flow fan Cross flow fan Although minimum efficiency requirements have been established for electric motors, including those that are part of a motor-fan system, most fans covered by the fans Regulation are used in combination with motors not covered by Regulation (EC) No 640/2009. Regarding coverage of fans integrated into other products, the working document on proposed regulation of these products under Directive 2009/125/EC states: Many fans are integrated in other products without being separately placed on the market or put into service within the meaning of Article 5 of Directive 2009/125/EC and of Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC. To achieve the full cost-efficient energy-saving potential, fans within a 125 W 500 kw power range integrated in other products should also be subject to the provisions of this Regulation. This potential regulation therefore has relevance to products covered in ENTR Lot 1. Pumps The pumps falling under the scope of the possible Ecodesign requirements are: Single stage end suction water pumps with characteristics as follows: o o o operating temperature between -10 and +120 C single suction, single impeller all efficiencies based on full (untrimmed) impeller 132 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

133 Vertical multistage (MS) water pumps with characteristics as follows: o o o o operating temperature between -10 and +120 C vertical multistage pumps in in-line and ring section design 2900 rpm pumps only efficiency is measured and judged on the basis of a 3 stage pump Submersible multistage (MSS) pumps with nominal size 4 and Legislation related to the lighting system The European Parliament and the Council of the European Union has issued a Directive 2000/55/EC of the European Parliament and of the Council on energy efficiency requirements for ballasts for fluorescent lighting put on the EU market, implemented via Regulation 245/2009, applying to electric mains-operated ballasts for fluorescent lighting sources as defined in European Standard EN 50294:1998. Mandatory ecodesign requirements apply to products placed on the market wherever they are installed, therefore such requirements cannot be made dependent on the application in which the product is used (such as office lighting or public street lighting) Legislations related to tertiary and domestic lighting Requirements for street lighting and office lighting are under development in the framework of the Ecodesign Directive 2009/125/EC. The draft legislation which was agreed by the Regulatory Committee in September 2008 sets requirements for linear and compact fluorescent lamps without integrated ballast, for high intensity discharge lamps, and for ballasts and luminaries able to operate such lamps. However, there are several limitations, for instance very small HID lamps now increasingly popular in the retail sector are not covered. Reflector lamps were covered under a separate piece of legislation on directional light sources (TREN Lot 19: Part 2). The products foreseen to be covered are used in streets and offices, but also in other applications (e.g. industrial plants, shops, public buildings). Depending on their specifications, the Ecodesign measure on commercial refrigeration could require that lights placed separately on the market and then integrated in refrigerating equipment comply with possible ecodesign requirements of tertiary and domestic lighting European Directive on Electromagnetic Compatibility (ECM) 2004/108/EC This Directive ensures that radio-communications operate in accordance with International Telecommunication Union (ITU) radio regulations, and that electrical supply networks and telecommunications networks, as well as equipment connected to them, are protected against electromagnetic disturbance European Directive on construction products 89/106/EEC Many manufacturers of insulating enclosures and panels used for walk-in cold rooms provide these components without any refrigeration appliance (condensing unit and/or evaporator). For these manufacturers, the CE mark and product Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 133

134 certification is based on Directive EC 89/106. The Directive covers the approximation of laws, regulations and administrative provisions of the Member States relating to construction products. Within Annex I: Essential requirements, it states: The construction works and its heating, cooling and ventilation installations must be designed and built in such a way that the amount of energy required in use shall be low, having regard to the climatic conditions of the location and the occupants. Essential requirements cover mechanical strength and stability, safety in the event of fire, hygiene, health and the environment, safety in use, protection against noise and energy economy and heat retention, as set out in Annex 1 to the Directive. ETAG 021 ( ) has been developed for cold storage room and cold storage building enclosure kits, and sets out methods for verification, assessment and attestation of the products. Only construction products that comply with the national standards transposing the harmonised standards into a European technical approval or, in the absence of such approvals, into national technical specifications complying with the essential standards are eligible to bear the "CE" marking to ensure that all construction works bearing the "CE" marking satisfy the essential requirements. It is up to the manufacturers or their representatives established in the Community to attest, either on the basis of their own resources or through an approved certification body, that their products conform to the requirements. Products which have been declared to conform with the Directive but which do not satisfy the essential requirements and therefore pose a health and safety threat may be temporarily withdrawn from the market by the Member States. Where non-conformity is attributable to the technical specifications, to their application or to omissions inherent therein, the Commission will decide, after consulting the Standing Committee on Construction, whether the European or national technical specification should or should not continue to enjoy presumption of conformity HEALTH AND SAFETY LEGISLATION The following pieces of legislation applies either to the product as an entity or to different stages of the manufacture process European Directive 95/16/EC on Machinery, amended by 2006/42/EC The Directive applies to machinery, defined as an assembly, fitted with or intended to be fitted with a drive system other than directly applied human or animal effort, consisting of linked parts or components, at least one of which moves, and which are joined together for a specific application. This Directive addresses essential health and safety requirements relating to the design and construction of machinery. These requirements are provided in the Annex IA of the Directive. Effective 29 June 2006, this Directive had to be transposed at the member state level before 29 June Before 29 December 2009, professional refrigeration products were covered only by the Low Voltage Directive (including service cabinets, horizontal refrigeration products and blast chillers). 125 ec.europa.eu/enterprise/sectors/construction/documents/legislation/cpd/index_en.htm 134 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

135 European Directive 2001/95/EC on General Product Safety This Directive covers all the products which are intended for consumers or likely, under reasonably foreseeable conditions, to be used by consumers even if not intended for them, and are supplied or made available in the course of a commercial activity, and whether new, used or reconditioned. The Directive requires producers to place only safe products on the market, and to provide information about risks. A safe product is defined as one which, under normal or reasonably foreseeable conditions of use including duration [ ] does not present any risk or only the minimum risks compatible with the product's use, considered to be acceptable and consistent with a high level of protection for the safety and health of persons [ ]. It obliges Member States to survey products on the market. This Directive is effective since 15/01/ European Directive 73/23/EEC on Low Voltage Equipments (LVD) According to the Directive, electrical equipment are defined as any equipment designed for use with a voltage rating of between 50 and V for alternating current and between 75 and V for direct current, other than the equipment and phenomena listed in Annex II of the Directive. This Directive covers all risks arising from the use of electrical equipment, including not just electrical ones but also mechanical, chemical (such as, in particular, emission of aggressive substances), health aspects of noise and vibrations, and ergonomic aspects as far as ergonomic requirements are necessary to protect against hazards in the sense of the Directive. The LVD lays down eleven safety objectives, which represent the essential requirements of this Directive. This Directive was amended by the Directive 93/68/EEC which adds that before being placed on the market, the electrical equipment referred to in Article 1 must have affixed to it the CE marking provided for in Article 10 attesting to its conformity to the provisions of this Directive, including the conformity assessment procedure described in Annex IV of the Directive Pressure Equipment Directive (PED) 1997/23/EC This Directive, effective since 29/11/1999, applies to the design, manufacture and conformity assessment of pressure equipment and assemblies with a maximum allowable pressure PS greater than 0.5 bars. This Directive establishes that the pressure equipment and the assemblies under the scope may be placed on the market and put into serve only if, when properly installed and maintained and used for their intended purpose, they do not endanger the health and safety of persons. The Directive also establishes technical requirements for equipment, listed in Annex I of the Directive. The compliment of the Directive is certified by the CE Marking European Directive 98/83/EC on quality of water The Directive 98/83/EC on quality of water intended for human consumption as for objective to protect human health from the adverse effects of any contamination of water intended for human consumption by ensuring that it is wholesome and clean. Directive requirements will need to be taken into Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 135

136 consideration for product categories using water for human consumption (i.e. beverage machines, water dispensers and ice-makers) Hazard Analysis Critical Control Point (HACCP) HACCP is an internationally recognised and recommended system for food safety management. It focuses on identifying the 'critical points' in a process where food safety problems (or 'hazards') could arise and puts in place preventative measures. This is sometimes referred to as 'controlling hazards'. Keeping records is also an important part of HACCP systems Summary of temperature and time constraints for cooked foodstuff The parameters of the post-cooking process in different countries within the EU are shown in the table below. Table 1-47: Summary of chilling temperature and time constraints within the EU Country Initial temperature ( C) Final temperature ( C) Time to reach final temperature (min) UK France Austria OTHER VOLUNTARY AGREEMENTS EUROVENT certification programmes for refrigeration components Eurovent also manages voluntary certification schemes for several refrigeration components, such as fan coil units, ducted fan coil units, air coolers for refrigeration, air cooled condensers, dry coolers, air handling units, and cooling and heating coils ASERCOM certification of refrigerant compressors The Association of European Refrigeration Compressor and Controls Manufacturers (ASERCOM) also provides a performance certification programme for refrigeration compressors. Its objective is to provide comparable and reliable data using common test methods, thus providing common reference points for all manufacturers DK demanufacture of refrigeration equipment 127 Since January 2006, a standard for the Demanufacture of Refrigeration Equipment was implemented in Danish law. The RAL quality mark GZ-728 is the European standard for the demanufacturing of refrigeration devices. These quality assurance and test specifications apply to the demanufacturing of waste refrigeration equipment containing CFCs. The specifications cover the collection, storage and processing of such equipment and the handling of the materials recovered prior to re-use or disposal RAL website: Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

137 SUMMARY OF EXISTING LEGISLATION AND VOLUNTARY MEASURES Table 1-48 summarises all existing mandatory and voluntary initiatives covering the product groups. Detailed conclusions by product group are discussed in the following sections. Some of these mandatory and voluntary standards, or elements of them, may be applicable to the EU context, and this will be discussed in further detail in Task 7 after technical, environmental and economic analysis of the Base Cases, Best Available Technology and improvement options. One important general consideration at this stage is the need for harmonised testing standards, through which appropriate and consistent evaluation of product performance can be made. Table 1-48: Summary of existing mandatory and voluntary standards Equipment EU US Canada Service Cabinets VEPS: UK ECA 128 VEPS: Energy Star, MEPS: DOE, CEC 129 AHRI 132 Blast cabinets Walk-in cold rooms Process chillers Remote condensing units N/A: No standards found FR AC D (Food safety) - VEPS: UK ECA 128 EU EUROVENT (A/C only) VEPS: UK ECA (air cooled only) MEPS 130 Australia / New Zealand (MEPS 131 for refrigerated display cabinets only) N/A N/A N/A MEPS: US minimum component requirements N/A N/A N/A MEPS 130 MEPS 133 N/A N/A N/A Service cabinets The terminology professional is better harmonised with current safety regulation definitions, such as the machinery and low voltage directives ( ), which require a declaration of intended use, distinguishing between household and professional use. This issue is potentially confused by the use of EN :2010 ( ) of some manufacturers for safety, which covers both domestic and similar equipment, for professional service cabinets. For food safety purposes, HACCP regulation effects the open display of food, while only the limits on M- package temperature described in EN ISO regulate food that is contained within equipment. The service cabinet product group has the greatest number of mandatory and voluntary standards of all the products covered in ENTR Lot 1. In the EU, service cabinets minimum energy performance requirements are only covered within the scope of the UK ECA. In third countries, regulations from Canada, Australia and the US could be taken into account to establish minimum energy performance 128 UK Enhanced Capital Allowance Scheme 129 California Appliance Efficiency Regulation 130 Canadian Energy Efficiency Regulation 131 AU/NZ Minimum Energy Performance Standards 132 Air Conditioning and Refrigeration Institute Certification Program 133 AU/NZ Minimum Energy Performance Standards Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 137

138 TEC (kwh/day) standards in EU 134.These are compared below to provide an idea of the ranges and variability of these standards, and some of the technical variations that might need to be taken into account should EU mandatory measures be considered. However, it must be noted that the limits set by different MEPS and VEPS are based on different measurement methodologies 135. These methodologies can lead to variation in resulting energy consumption figures of 5 to 10% for an identical product. The graphs below, Figure 1-25 to Figure 1-28, are provided to demonstrate different approaches, and should not be used for direct comparison of the MEPS levels (where different test methodologies are used) Refrigerator MEPS and VEPS HT; Plug-in; Vertical (US CEC) HT; Plug-in; Any type (CAN EER) 8.00 HT; Plug-in; Vertical; 1-door (UK ECA) HT; Plug-in; Vertical; 2-door (UK ECA) HT; Plug-in; Counter and under-counter (UK ECA) HT; Remote; Vertical or horizontal (US DOE and CAN EER) HT; Plug-in; Vertical; 0 <= net volume < 425 litres (Energy Star) HT; Plug-in; Any type (CEE Tier 2: US CEC +40%) Net volume (litres) HT; Plug-in; Vertical; 425 <= net volume < 849 litres (Energy Star) HT; Plug-in; Vertical; 849 <= net vlume < 1416 litres (Energy Star) HT; Plug-in; Vertical; Net volume >= 1416 litres (Energy Star) HT; Plug-in; Chest (Energy Star) Figure 1-25: Comparison of MEPS and VEPS for refrigerator (HT) service cabinets 134 The North-American approach to MEPS for refrigerated cabinets is a formula X*V + Y where volume is defined in ft³. For detailed information on the US and Canadian MEPS for storage cabinets, please refer to section Hence, if one considers an appliance of 500l internal net volume, the limit of Energy Star might be 2,3 kwh/day while the limit of the UK ECA is 4 kwh/day, but an identical appliance may satisfy both limits due to the different test methodologies used to assess the energy consumption. Source: Electrolux. 138 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

139 TEC (kwh/day) TEC (kwh/day) Freezer MEPS and VEPS LT; Plug-in; Vertical; 2-door (UK ECA) LT; Plug-in; Net vilume >= 340 litres (CAN EER) LT; Plug-in; Vertical; 1-door (UK ECA) LT; Plug-in; Counter and under-counter (UK ECA) LT; Plug-in; Net volume < 340 litres (CAN EER) LT; Plug-in; Vertical (US CEC) LT; Remote; Vertical (US DOE and CAN) Net volume (litres) LT; Plug-in; Any type (CEE Tier 2: Energy Star/US CEC +30%) LT; Plug-in; Vertical; 0 <= net volume < 425 litres (Energy Star) LT; Plug-in; Vertical; 425 <= net volume < 849 litres (Energy Star) LT; Plug-in; Vertical; 849 <= net volume < 1416 litres (Energy Star) LT; Plug-in; Vertical; net volume >= 1416 litres (Energy Star) LT; Plug-in; Chest (Energy Star) Figure 1-26: Comparison of MEPS and VEPS freezer (LT) service cabinets Refrigerator/freezer MEPS HT/LT; Plug-in; refrigerator:freezer volume 50:50 (US CEC) HT/LT; Plug-in; refrigerator:freezer volume 50:50 (CAN EER) Net volume (litres) Figure 1-27: Comparison of MEPS for refrigerator-freezer (HT/LT) service cabinets In general, apart from the US CEC MEPS at low net volume, remote product standards are more stringent than those for plug-in products. In addition, it is interesting to note that different ranges of standards have been set for distinct Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 139

140 TEC (kwh/day) ranges of product net volumes in the UK ECA and CAN EER schemes. Finally, through examination of the US DOE and CEC MEPS, and the UK ECA VEPS, it appears that there is significant variation in the differentiation of similar products across operation temperatures by mandatory and voluntary schemes, as shown below Refrigerator MEPS and VEPS vs freezer MEPS and VEPS HT; Remote; Vertical or horizontal (US DOE and CAN EER) HT; Plug-in; Vertical (US CEC) HT; Plug-in; Vertical; 1-door (UK ECA) HT; Plug-in; Vertical; 2-door (UK ECA) HT; Plug-in; Counter and under-counter (UK ECA) LT; Remote; Vertical (US DOE and CAN) LT; Plug-in; Vertical (US CEC) 5.00 LT; Plug-in; Vertical; 1-door (UK ECA) LT; Plug-in; Vertical; 2-door (UK ECA) Net volume (litres) LT; Plug-in; Counter and under-counter (UK ECA) Blast cabinets Figure 1-28: Comparison of MEPS and VEPS for refrigerator and freezer service cabinets No legislation, minimal energy performance standards or agreements concerning blast equipment have been identified Walk-in cold rooms Currently there are no mandatory or voluntary minimum performance standards for walk-in cold rooms, only minimum component requirements set by the US. A testing standard is under development by the US DOE, and MEPS are due to be defined in around 2013 (three years after final rule on testing standards is made). 140 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

141 COP (net cooling capacity (kw) / effective power input (kw) in cooling mode) Process chillers MEPS from UK, USA, Canada, and Australia are summarised in Figure In the graph is shown how Canada and USA share the same level of strictness for chillers. These standards are related only to packaged units. All of the values are reported with respect to COP. The least demanding scheme is the UK ECA, which requires half of the efficiency for equipment then its American equivalent. The UK ECA scheme and standard AS/NZS 4776:2008 could be used as a model to develop energy performance requirements for Packaged Chillers in the EU. Nevertheless, their ranges of classification are different and any approach developed would need to be homogenised. As for all other products within the scope, it is very important to take into account the type of refrigerant for environmental reasons. However, the energy performance of the equipment is more related to the configuration than the employed refrigerant MEPS and VEPS for Chillers ECA - Split air-cooled chiller (all compressors) ECA - Packaged air-cooled chiller (all compressors) ECA - Water-cooled (all compressors) ASHRAE - Air-cooled w/o condenser ASHRAE - Water-cooled reciprocating ASHRAE - Centrifugal ASHRAE - Screw CAN - Air-cooled packaged CAN - Air-cooled split CAN - Water-cooled reciprocating CAN - Water-cooled rotary/screw/scroll CAN - Water-cooled centrifugal AS/NZ - Air-cooled AS/NZ - Water-cooled Cooling capacity (kw) Base Case MT BAT MT Figure 1-29 MEPS and VEPS for Chillers from third countries and the UK Remote condensing units Only the UK ECA scheme establishes voluntary minimum standards, for air-cooled remote condensing units. They are summarised in the figure and table below. There is no minimum energy performance standard for remote condensing units. 136 Mark Ellis, consultation Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 141

142 COP (net cooling capacity (kw) / effective power input (kw) in cooling mode) 4,5 VEPS for air condensign units 4 3,5 3 2,5 2 UK ECA Scheme 1,5 1 0, C -10 C 5 C Temperature category Figure 1-30: VEPS for remote condensing units Presented below are the UK ECA performance levels, with respective operating conditions. Table 1-49: VEPS for remote condensing units 142 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

143 1.5. CONCLUSIONS FOR TASK 1 The preliminary discussions and scope presented in Task 1 outlined the key issues and parameters related to the products relevant to the ENTR Lot 1. Initial classifications for the product groups have been defined by category. Accurate classifications are crucial to allow effective market data collection, which in turn will ensure that the Base Cases (the current average products) to be analysed in Task 4 are accurately reflecting the market. Testing standards have been adapted for use with service cabinets, and others are available for chillers and remote condensing units. Walk-in cold rooms and blast cabinets are however lacking energy consumption testing standards in the EU, although there is scope for development of these, based on the FR NF AC D for blast cabinets and the AHRI 1200/DOE approach for walk-in cold rooms. The identification of the relevant legislation worldwide reveals that many third countries have already developed obligatory minimum standards for some product categories but that harmonised international or EU standards are relatively lacking. For some product categories, voluntary programmes exist in the EU whose purpose is to provide a tool for comparison of competing products and also to set any energy efficiency requirements (e.g. UK ECA). The US Energy Star experience shows that companies offering Energy Star refrigerated display cabinets make up over 90% of the market and about products qualify in this range of products. There are therefore clear avenues for development of both testing and performance standards, which could be based upon existing initiatives. Existing mandatory and voluntary minimum standards may provide a basis for EU MEPS and will be further analysed in Task 7. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 143

144 ANNEXES 144 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

145 This page is left intentionally blank Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 145

146 Annex 1-1: Additional standards related to refrigeration and freezing equipment This annex provides a source of additional information, listing standards related to products covered in ENTR Lot 1 that are not directly relevant to the study. Systemrelated standards will de described in the technical annex EN 153:2006 Relevance: Service cabinets The EN 153:2006 (superseding EN 153:1995) Methods of measuring the energy consumption of electric mains operated household refrigerators, frozen food storage cabinets, food freezers and their combinations, together with associated characteristics is the main EU harmonised standard used for the measurement of the energy consumption of refrigerators and freezers. This standard was prepared by European Committee for Standardisation/Technical Committee CEN/TC 44. Scope: Household refrigerators, frozen food storage cabinets, food freezers and similar equipments This standard is used for household refrigeration appliances but can be used by the industry to test commercial refrigeration appliances which are similar to household refrigerators and freezers such as plug-in service cabinets (industry common practice). Though, further specifications may be necessary for the testing requirements of such products as they do not operate in a home (e.g. the frequency of door opening might be an important parameter for service cabinets as they are more intensively used than household appliances). The use of EN 153 has been superseded by EN ISO 23953, according to stakeholders. Requirements: EN 153 proposes a test method to be applied and defines control procedures for checking values declared by the manufacturers. Regarding testing methods EN 153 references to the EN ISO 15502:2005 (see next standard), but includes some modifications to conform its requirements to the EU legislation on rational use of energy i.e. Directive 2003/66/EC, and in particular: 146 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

147 in Clause 5 Design, only clause 5.1 and 5.6 of EN ISO apply. In order to enable direct comparison between all climate class appliances for the checking of energy consumption, the test temperature is always set at +25 C for all class (SN, N, ST, and T (see Table 1-50 for class description) the refrigerating appliance with a rated voltage within the range between 220V and 240V shall be tested at 230V ± 1% with a frequency of 50 Hz ± 1% a specific normative Annex C Rated characteristics and control procedure, was set, which has an informative nature in EN/ISO 15502, and deals with the control procedure of the declared values, which is fundamental for the verification of the compliance to any legislation on cold appliances. The main changes in EN 153:2006 compared to the previous 1995 edition are: the rated voltage to test the refrigerating appliances, changed from 220V to 230V inclusion of a correction formula for the energy consumption measured value, to be normalised at ambient temperature = +25 C; when possible ambient temperature range is from C to C addition of a normative annex on built-in refrigerating appliances addition of reference to Directives 94/2/EC and 92/75/EEC editorial modifications to be consistent with EN ISO EN ISO 15502:2005 (CORRIGENDUM 1:2007) Relevance: Service cabinets The EN ISO 15502:2005 (corrigendum 1:2007) test method related to Household refrigerating appliances - Characteristics and test methods, prepared by Technical Committee ISO/TC 86, Refrigeration and air-conditioning, Subcommittee SC 5, Testing and rating of household refrigeration appliances is the internationally recognised standard which specifies the essential characteristics of household refrigerating appliances, factory assembled and cooled by internal natural convection or forced air circulation. Scope: Household refrigerating appliances and similar appliances (e.g. plug-in service cabinets) This test method is applicable to plug-in service cabinets as these appliances are very similar to household appliances (common practice in the industry). As mentioned for EN ISO 153:2006, further specifications could be set for the testing requirements for these products. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 147

148 Requirements: The EN ISO 15502:2005 standard describes the following specifications: essential characteristics of household refrigerating appliances, factory assembled, and cooled by internal natural convection or forced air circulation: o refrigerating appliances types o compartments and sections fresh food compartment cellar compartment chill compartment ice-making compartment frozen food compartment one, two, or three star compartment food freezer compartment/four star compartment two star section (part of a food freezer compartment or cabinet, or three-star compartment or cabinet) o physical aspects and dimensions o definitions relating to performance characteristics, including: freezing capacity ice-making capacity defrost types o definitions relating to refrigerating system o symbols o classification in climatic classes: SN, N, ST, T Table 1-50: Climatic classes of Household refrigerating appliances (EN ISO 15502) Class Symbol Ambient temperature range ( C) Extended temperate SN +10 to +32 Temperate N +16 to +32 Subtropical ST +16 to +38 Tropical T +16 to +43 in refrigerator-freezer types: type I and type II (depending in the number of user-adjustable temperature control devices) o materials, design and manufacture characteristics o storage temperatures: 148 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

149 Table 1-51: Refrigerating appliances storage temperatures in C (EN ISO 15502) Fresh food storage compartment t 1m, t 2m, t 3m 0 t1m, t2m, t3m 8 T m a +4 Food freezer and three-star compartment/cabine t Storage temperature in C Two-star compartmen t / section One-star compartmen t Cellar compartmen t Chill compartmen t t*** t** t* t cc t cc -18 a -12 a t cm t cc +3 a as a result of a defrost cycle, the storage temperatures of frost free and/or adaptive defrost refrigeration appliances are permitted to rise by no more than 3K during a period not greater than 4 hours or 20% of the duration of the operating cycle, whichever is the shorter. t cc instantaneous temperature value (cellar or chill compartment); t ma arithmetic average of t 1m, t 2m, t 3m test methods for the determination of o linear dimensions, volumes and areas: linear dimensions (shall be measured to the nearest millimetre volumes of compartments and sections (shall be expressed to the nearest whole number of cubic decimetres or of litres): gross volume, total storage volume, storage volume of fresh-food storage, chill, cellar, ice-making compartments; food freezer compartments/cabinets and frozen-food storage compartments/cabinets; two-star sections volumes of shelves and partitions storage shelf area o air tightness of seals of doors, lids, and drawers o mechanical strength of shelves and similar components o storage temperatures o water vapour condensation: to determine the extent of condensation of water on the external surface of the cabinet under specified ambient conditions (temperature and relative humidity) o energy consumption: to measure the energy consumption of refrigerating appliances under specified test conditions, calculated for a period of exactly 24h from the measured value, and expressed in kilowatt-hours per 24h (kwh/24h), to two decimal places. o Temperature rise time: to check the time for the temperature rise of test packages from -8 C to -9 C o Freezing capacity of food freezers and food freezer compartments, loaded with test packages o Ice making capacity of appliance in the ice tray or in the automatic ice-maker, in kilograms of produced in 24h (kg of ice/24h) test conditions: o ambient temperature and humidity Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 149

150 for checking the storage temperatures, the ambient temperature shall be: +10 C and +32 C for appliances in class SN +10 C and +32 C for appliances in class N +10 C and +32 C for appliances in class ST +10 C and +32 C for appliances in class T For checking the energy consumption, temperature rise time, freezing capacity and ice-making capacity of all cold appliances the ambient temperature shall be +25 C for class SN, N, ST and +32 C for class T for other tests: at temperature stated in the test specifications o installation of the test appliances o test packages o operating requirements of the test appliances o measuring instruments o final test report requirements type of marking and information to be included in the rating plate technical and commercial product information instructions for users Following a formal request started in 2003 by some Member States, the ISO technical management board agreed to transfer the responsibility for standards on the performance and rating of household refrigerators and freezers from ISO to IEC which was confirmed by IEC with AC/28/2006 in September A new Sub- Committee SC 59M (Performance of electrical household and similar cooling and freezing appliances) has been created within IEC TC59 (Performance of household and similar electrical appliances), the Technical Committee already addressing other home appliances EN 28960:1993 (ISO 8960:1991) Relevance: Service cabinet The EN 28960:1993 (ISO 8960:1991) standard related to Refrigerators, frozen food storage cabinets and food freezers for household and similar use Measurement of emission of airborne acoustical noise is linked to the international standard on noise measurement IEC with replacement or additions to conform to the specificities of refrigerating and freezing appliances. This standard is currently under revision ANSI/ARI The ANSI/ARI standard Performance rating of forced-circulation freedelivery unit coolers for refrigeration establishes for forced-circulation freedelivery unit coolers for refrigeration: definitions; test requirements; rating requirements; minimum data requirements for Published Ratings; marking and nameplate data; and conformance conditions. Scope: This standard applies to factory-made, Forced-Circulation, Free-Delivery Unit Coolers, operating with a Volatile Refrigerant fed by either direct expansion or liquid overfeed at wet and/or dry conditions. 150 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

151 Exclusion: This standard does not apply to air-conditioning units used primarily for comfort cooling for which testing methods are given in other standards, unit coolers operating at latent load conditions with refrigerant saturation temperature < 32 ºF (0.0 ºC) to prevent frost, unit coolers installed in or connected to ductwork, unit coolers using zeotropic refrigerants with glides greater than 2.0 ºF (1.1 ºC), field testing of unit coolers ANSI/ARI The ANSI/ARI standard Rating of Sound and Vibration for Refrigerant Compressors establishes the rating of sound and vibration for refrigerant applies to External-drive, Hermetic and Semi-Hermetic Refrigerant Compressors. In the case of External-drive Refrigerant Compressors, the driving mechanism shall be excluded from the sound and vibration measurements. However, for Semi- Hermetic Refrigerant Compressors where compressors. It the driving mechanism is an integral part of the compressor assembly, it shall be included in the measurements ANSI/ARI The ANSI/ARI standard Performance rating of positive displacement condensing units establishes, for positive displacement condensing units: definitions; test requirements; rating requirements; minimum data requirements for published ratings; operating requirements; marking and nameplate data and conformance conditions. Scope: This standard applies to electric motor driven, single and variable capacity positive displacement condensing units for air-cooled, evaporatively-cooled, and water-cooled refrigeration applications. Exclusions: This standard does not apply to condensing units intended for use in household refrigerators and freezers, automotive air-conditioners, dehumidifiers. Test Requirements: The tests required for this standard shall be conducted in accordance with ASHRAE Standard 23 (see ASHRAE standards) ANSI/ARI The ANSI/ARI standard Performance rating of positive displacement refrigerant compressors and compressor units establishes, for single and variable capacity positive displacement refrigerant compressors and compressor units: definitions; test requirements; rating requirements; minimum data requirements for published ratings; operating requirements; marking and nameplate data and conformance conditions. Scope: This standard applies to electric motor driven, single and variable capacity positive displacement refrigerant compressors and compressor units. This standard also applies to the presentation of performance data for positive displacement refrigerant compressors and compressor units for air-cooled, evaporatively-cooled or water-cooled air-conditioning, heat pump and refrigeration applications. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 151

152 Exclusions: This standard does not apply to compressors and compressor units employing ammonia (covered in ARI Standard 510) and compressors and compressor units intended for use in household refrigerators and freezers, automotive air-conditioners and dehumidifiers Test Requirements: The tests required for this standard shall be conducted in accordance with ASHRAE Standard 23 (see ASHRAE standards). Rating conditions: Table 1-52 and Table 1-53 present standard rating conditions for compressors and compressor units respectively for commercial refrigeration and air conditioners and heat pumps applications. 152 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

153 Table 1-52: Standard rating conditions for compressors and compressor units for commercial refrigeration applications Table 1-53: Standard rating conditions for compressors and compressor units used in air conditioners and heat pumps Rating requirements: General performance data, covering the operational spectrum of the equipment, must be presented in tabular form and include: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 153

154 Suction dew point temperature range, F [ C] Discharge dew point temperature range, F [ C] Applicable superheat, F [ C] Power Input, W [W] Compressor or Compressor Unit Efficiency, percent Refrigerant mass flow rate, lb/h [kg/s] Current, A [A] Refrigerant designation per ASHRAE Standard 34 Performance Data must be reported for the following conditions for the compressor or compressor unit application depending on the usage intended (extreme ends of the data may be omitted and not reported due to limits of acceptable operation of the compressor or compressor unit as determined by the manufacturer): ISO 5149:1993 Air-Conditioning (including heat pumps): o -10 F to 55 F [-23 C to +13 C] suction dew point temperature in +5 F [+3 C] increments o +80 F to +140 F [+27 C to +60 C] discharge dew point temperature in +10 F [+5.6 C] increments o Return gas temperature per Table 1-53 High Temperature (water coolers and walk-in coolers, for example): o +20 F to +50 F [-7 C to +10 C] suction dew point temperature in +5 F [+3 C] increments o +80 F to +140 F [+27 C to +60 C] discharge dew point temperature in +10 F [+5.6 C] increments o Return gas temperature per Table 1-52 Medium Temperature (service cabinets, for example): o -10 F to +32 F [-23 C to 0 C] suction dew point temperature in +5 F [+3 C] increments o +80 F to +140 F [+27 C to +60 C] discharge dew point temperature in +10 F [+5.6 C] increments o Return gas temperature per Table 1-52 Low Temperature (freezer cases, for example): o -40 F to +10 F [-40 C to -12 C] suction dew point temperature in +5 F [+3 C] increments o +80 F to +140 F [+27 C to +60 C] discharge dew point temperature in +10 F [+5.6 C] increments o Return gas temperature per Table 1-52 International standard ISO 5149:1993 (not a standard endorsed by any of the European Standards Bodies) Mechanical refrigerating systems used for cooling and heating safety requirements. Scope: All types of refrigerating systems in which the refrigerant is evaporated and condensed in a closed circuit, including heat pumps and absorption systems, except for systems using water or air as the refrigerant. It is applicable to new 154 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

155 refrigerating systems, extensions and modifications of already existing systems, and for used systems. Requirements: This standard specifies the requirements relating to the safety of persons and property for the design, construction, installation and operation of refrigerating systems. It gives a classification of the refrigerating systems ATP AGREEMENT INTRODUCTION As described in and , ATP is a multi-lateral agreement for overland cross-border carriage of perishable foodstuffs. It ensures that vehicles used for this carriage meet agreed international standards, which apply to the bodywork (insulating box) and refrigeration systems. Published by the United Nations, includes: the terms of the agreement and a list of signatories; definitions and classifications of equipment; provisions relating to the checking for compliance; methods and procedures for measuring the insulating capacity and the efficiency of the refrigeration system; requirements for the monitoring of air temperature during use; requirements for food sampling during use; and temperature requirements for various chilled foodstuff DEFINITIONS Insulated equipment. Equipment of which the body is built with insulating walls, doors, floor and roof. K coefficient. The overall heat transfer coefficient (K coefficient) of the insulated equipment. I N = Normally insulated equipment I R = Heavily insulated equipment Mechanically refrigerated equipment. Insulated equipment either fitted with its own refrigerating appliance, or served jointly with other units of transport equipment by such an appliance (fitted with either a mechanical compressor, or an "absorption" device, etc.). 6 classes of refrigerating equipment (A to F) aredescribed, able to maintain temperature below a certain maximum (or within a specific range), with a mean external ambient temperature of +30 C. Refrigeration unit. Packaged refrigeration system. W O = Refrigerating capacity of a refrigeration unit when the evaporator is free from frost T i = inside temperature REQUIREMENTS The mechanically refrigerated equipment shall be capable, with a mean outside temperature of + 30 C, of lowering the temperature T i inside the empty body to, and thereafter maintaining it continuously in the following manner at: Class A: T i may be chosen between + 12 C and 0 C inclusive; Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 155

156 Class B: T i may be chosen between + 12 C and - 10 C inclusive; Class C: T i may be chosen between + 12 C and - 20 C inclusive. Class D: T i is equal to or less than 0 C; Class E: T i is equal to or less than - 10 C; Class F: T i is equal to or less than - 20 C. In the case of classes A, B and C, any desired practically constant T i (in conformity with the standards defined above), while in the case of classes D, E and F a fixed practically constant T i (in conformity with the standards defined above). The K coefficient of equipment of classes B, C, E and F shall in every case be equal to or less than 0.40 W/m 2.K (classes that are required to go down to (or below) - 10 C). Testing stations shall be provided with the equipment and instruments necessary to ensure that the K coefficient is determined with a maximum margin of error of ±10% when using the method of internal cooling and ±5% when using the method of internal heating. The overall coefficient of heat transfer (K coefficient), is such that the equipment is assignable to one or other of the following two categories: I N specified by a K coefficient equal to or less than 0.70 W/m 2.K; I R specified by a K coefficient equal to or less than 0.40 W/m 2.K and by sidewalls with a thickness of at least 45mm for transport equipment of a width greater than 2.50m. If the refrigerating appliance with all its accessories has undergone separately, to the satisfaction of the competent authority, a test to determine its effective refrigerating capacity at the prescribed reference temperatures, the transport equipment may be accepted as mechanically refrigerated equipment without undergoing an efficiency test if the effective refrigerating capacity of the appliance in continuous operation exceeds the heat loss through the walls for the class under consideration, multiplied by the factor For insulated bodies, the manufacturer s plate shall be on the outside of the body. The manufacturer s plate shall show clearly and indelibly at least the following particulars: Country of manufacture or letters used in international road traffic; Name of manufacturer or company; Model (figures and/or letters); Serial number; Month and year of manufacture. Industry estimates that insulation will deteriorate at about 5% per annum, therefore fuel costs will increase proportionally. In order to ensure the best performance of the refrigeration equipment, maintenance should be carried out at regular intervals, comprising of: Refrigerated unit servicing Temperature control thermostat calibration check Thermostat and temperature recorder calibration check 156 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

157 Inspection of the bodywork for holes/damage. This should be promptly repaired with the correct materials to ensure that insulation deterioration due to moisture ingress is kept to a minimum. Inspection of door operation and seal condition to prevent the ingress of dust, moisture and undesirable odours, as well as air leakage/temperature loss TEST METHODS AND PROCEDURES (ANNEX 1, APPENDIX 2 OF THE AGREEMENT) The following extracts and summaries of the requirements of the testing procedures and methods are described (including relevant section numbers) Definitions and general principles (Section 1) The overall heat transfer coefficient (K coefficient) of the special equipment is defined by the following formula: K = W / S. ΔT where W is either the heating power or the cooling capacity, as the case may be, required to maintain a constant absolute temperature difference ΔT between the mean inside temperature T i and the mean outside temperature T e, during continuous operation, when the mean outside temperature T e is constant for a body of mean surface area S. The mean surface area S of the body is the geometric mean of the inside surface area Si and the outside surface area S e of the body: S = (S i. S e ) In determining the two surface areas S i and S e, structural peculiarities and surface irregularities of the body, such as chamfers, wheel-arches and similar features, shall be taken into account and shall be noted under the appropriate heading in test reports; however, if the body is covered with corrugated sheet metal the area considered shall be that of the plane surface occupied, not that of the developed corrugated surface. Temperature measuring points (1.3) Describes the positions of 12 measuring points inside, and 12 measuring points outside, of the insulated equipment are specified. The mean temperature of the walls is the arithmetic mean of the mean of the outside temperatures and the mean of the inside temperatures. Steady state period and duration of test (1.7) Describes the permitted variance of the mean outside and inside temperatures, and the heating power (or cooling capacity) during the steady state period Insulating capacity of equipment (Section 2) Section 2 sets out procedures for measuring the K coefficient of the insulated box. Test method (2.1.2) The K coefficient shall be measured in continuous operation either by the internal cooling method or by the internal heating method. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 157

158 Describes the specifications for these two test options. Test procedure (2.1.4) In either case, the empty body shall be placed in an insulated chamber whose mean temperature shall be kept uniform to within ±0.5K, to a level where the temperature difference between the inside of the body and the insulated chamber is 25 C ±2K, the average temperature of the walls of the body being maintained at +20 C ±0.5K. Also describes the air flow and other requirements. Verification of the K coefficient (2.3.1) If the test is solely to test the K coefficient, the tests can be stopped one the steps as described above have been met. Accuracy of the K coefficient (2.3.2) Minimum margin of error is ±10% for internal cooling method and ±5% for internal heating method Effectiveness of thermal appliances [applications] of the equipment (Section 3) Section 3 sets out procedures for testing that the whole product (insulated box plus refrigeration system) meets the performance requirements in terms of achieving the given temperature classification. Test method (3.2.1) The empty body shall be placed in an insulated chamber whose mean temperature shall be kept uniform, and constant to within ± 0.5K, at + 30 C. The mass of air in the chamber shall be made to circulate as specified in section 2, and the temperature measuring instruments protected against radiation shall be placed inside and outside the body at the points specified in section 1. Test procedure (3.2.2) When the mean inside temperature of the body reaches the outside temperature (+30 C), the doors, hatches and other openings shall be closed and the refrigerating appliance and the inside ventilating appliances (if any) shall be started up at maximum capacity. In addition, in the case of new equipment, a heating appliance with a heating capacity equal to 35% of the heat exchanged through the walls in continuous operation shall be started up inside the body when the temperature prescribed for the class to which the equipment is presumed to belong has been reached. Criterion of satisfaction (3.2.5) The test shall be deemed satisfactory if the refrigerating appliance is able to maintain the prescribed temperature conditions during the said 12-hour periods, with any automatic defrosting of the refrigerating unit not being taken into account Procedure for measuring the effective refrigerating capacity of unit when evaporator is free from frost (Section 4) Section 4 sets out procedures for measuring refrigeration system cooling capacity. 158 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

159 General principles (4.1) Refrigerating capacity, W O, of a unit when the evaporator is free from frost can be calculated by attachment to either a calorimeter box or the insulated body of a unit of transport equipment, operating continuously, and this can be described as: W o = W j + U. ΔT where: U is the heat leakage of the calorimeter box or insulated body, Watts/ C; ΔT is the difference between the mean inside temperature T i and the mean outside temperature T e of the calorimeter or insulated body (K); W j is the heat dissipated by the fan heater unit to maintain each temperature difference in equilibrium. Test method (4.2) Describes in detail the calculation methods, instrumentation (4.2.2), conditions (4.2.3), and procedure (4.3) for calculation of the refrigeration unit capacity, both for tests using the methodology described in section 2, or the calorimeter box method (it is preferable to use a calibrated calorimeter box to obtain maximum accuracy). However, it is sufficient to measure U directly, the value of this coefficient being defined by the following relationship where: U = W / ΔT m where: W is the heating power (in watts) dissipated by the internal heater and fans; ΔT m is the difference between the mean internal temperature T i and the mean external temperature T e ; U is the heat flow per degree of difference between the air temperature inside and outside the calorimeter box or unit of transport equipment measured with the refrigeration unit fitted. The calorimeter box or unit of transport equipment (insulated box) is placed in a test chamber, and both should be heavily insulated. If a calorimeter box is used, U. Δ T should be not more than 35% of the total heat flow W o. Test result (4.4) The refrigeration capacity for ATP purposes is that relating to the mean temperature at the inlet(s) of the evaporator (temperature measuring instruments protected against radiation) Checking the insulating capacity of equipment in service (Section 5) General examination of the equipment (5.1) Checking the insulating capacity of equipment in service can be carried out through the methods described in section 2, or a general examination which investigates aspects such as the condition of the walls and insulation. An examination of air-tightness (5.2) should also be carried out, with an observer stationed inside the equipment, which has been placed in a brightly-illuminated area (or other improved method). Decisions (5.3) If the condition of the equipment is judged as acceptable, it can be kept in service in its class for no more than 3 years. If not, tests as described in section 2 should Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 159

160 be undertaken. Heavily insulated equipment, if not accapted as suitable for its class, may be used as normally insulated for a further 3 years. If the inspection applies to a type approved series, each unit should be inspected and 1% should be tested under conditions specified in section 2. If acceptable, the units can be kept in service for a further 6 years Verifying the effectiveness of thermal appliances of equipment in service (Section 6) Mechanically refrigerated equipment (6.2) Checking of the thermal performance of mechanically refrigerated equipment in service can be carried out through the methods described in section 3, or alternatively through the examination as described in section 5, and in addition it shall be verified that, when the outside temperature is not lower than + 15 C, the inside temperature of the empty equipment can be brought to the class temperature within a maximum period (in minutes), as prescribed in table X. Table 1-54: ATP refrigeration equipment in-service test requirements If the equipment was brought into service before the signing of the agreement, it shall be verified that, when the outside temperature is not lower than + 15 C, the inside temperature of the empty equipment, which has been previously brought to the outside temperature, can be brought within a maximum period of 6 hours: In the case of equipment in classes A, B or C, to the minimum temperature, as prescribed; In the case of equipment in classes D, E or F, to the limit temperature, as prescribed. Temperature measuring points are described for this test procedure (6.4). Provisions (6.5) If accepted, the equipment can be kept in service for a further 3 years. In not accepted, the tests decribed in section 3 must be carried out, and if then accepted the equipment may be kept in service for a further period of six years. If the test applies to a type approved series, each thermal appliance should be inspected for general condition and the effectiveness of 1% of the refrigeration uinits should be tested under conditions specified in section 3. If acceptable, the units can be kept in service for a further 6 years COMPLIANCE AND ENFORCEMENT Checks for conformity with the standards shall be made: (a) before equipment enters into service; (b) periodically, at least once every six years; 160 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

161 (c) whenever required by the competent authority. Except in the cases provided for in appendix 2, sections 5 and 6 of the agreement, the checks shall be made at a testing station designated or approved by the competent authority of the country in which the equipment is registered or recorded, unless, in the case of the check referred to in (a) above, a check has already been made on the equipment itself or on its prototype in a testing station designated or approved by the competent authority of the country in which the equipment was manufactured. A certificate of compliance with the standards shall be issued by the competent authority of the country in which the equipment is to be registered. This documentation, or the required manufacturer s plate, can be used by competent authorities for identification during inspection. Product ranges can be Type Approved to the required standards, after testing of one unit, after which Type Approval certification lasts for 6 years. The competent authority shall take steps to verify that production of other units is in conformity with the approved type. For this purpose it may check by testing sample units drawn at random from the production series. After 6 years, it is possible to renew the certification for 3 year periods by having an in-service K coefficient test at an approved ATP Designated Station authorised by any country that is a signatory to the agreement. If, in the course of the six-year period, the production series exceeds 100 units, the competent authority shall determine the percentage of units to be tested. If a vehicle fitted with equipment does not have an ATP certificate, and no Type Approvals have been issued, then the only option is to obtain a certificate by having a one off test at an approved test centre or at the owner s site. A unit shall not be regarded as being of the same type as the unit tested unless it satisfies the following minimum conditions: (i) If it is insulated equipment, the construction shall be comparable and, in particular, the insulating material and the method of insulation shall be identical: (ii)... the thickness of the insulating material shall be not less than that of the reference equipment; the interior fittings shall be identical or simplified; the number of doors and the number of hatches or other openings shall be the same or less; and the inside surface area of the body shall not be as much as 20% greater or smaller. (iii) If it is mechanically refrigerated equipment, in which case the reference equipment shall be either:... (a) mechanically refrigerated equipment; the conditions set out in (i) above shall be satisfied; and the effective refrigerating capacity of the mechanical refrigeration appliance per unit of inside surface area, under the same temperature conditions, shall be greater or equal; Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 161

162 or (b) insulated equipment to which it is intended to have fitted, at a later date, a mechanical refrigeration unit and which is complete in every detail but with the refrigeration unit removed and the aperture filled, during the measurement of the K coefficient, with close fitting panels of the same overall thickness and type of insulation as is fitted to the front wall. In which case: the conditions set out in (i) above shall be satisfied; and the effective refrigerating capacity of the mechanical refrigeration unit fitted to insulated reference equipment shall be as defined. 162 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

163 1.15. OTHER RELATED STANDARDS EN 13215:2000: Condensing units for refrigeration rating conditions, tolerances and presentation of manufacturer s performance data EN 12900:2005: Refrigerant compressors - Rating conditions, tolerances and presentation of manufacturer's performance data The purpose of this norm is to specify the rating conditions, tolerance and method of presenting data for positive displacement refrigerant compressors. Single stage and single and two stage compressors using liquid for sub-cooling are included. The results obtained can be used as comparative parameters between equipments. EN :2006: Pressure equipment for refrigerating systems and heat pumps - Part 1: Vessels - General requirements EN 13313:2001: Refrigerating systems and heat pumps - Competence of personnel EN 12178:2003: Refrigerating systems and heat pumps - Liquid level indicating devices - Requirements, testing and marking EN 13136:2001: Refrigerating systems and heat pumps - Pressure relief devices and their associated piping - Methods for calculation EN 1861:1998: Refrigerating systems and heat pumps - System flow diagrams and piping and instrument diagrams - Layout and symbols EN 12284:2003: Refrigerating systems and heat pumps - Valves - Requirements, testing and marking EN 12900:2005: Refrigerant compressors - Rating conditions, tolerances and presentation of manufacturer's performance data EN 12524:2000. Building materials and products. Hygrothermal properties. Tabulated design values. ISO 6946:2007: Building components and building elements Thermal resistance and thermal transmittance Calculation method This document provides the calculation method for thermal properties od building components and elements (walk-in cold rooms included). It also states approximate method to be used in inhomogeneous layers. BS EN 14509:2006: Self-supporting double skin metal faced insulating panels. Factory made products. Specifications CWA 15596:2006: The CEN Work Agreement CWA 15596:2006 defines the Code of practice on cleanability of commercial food equipment used in the retail and catering sectors. It is linked to the main standard on safety requirements IEC CWA is not a standard in a formal document and deals with cleanability, construction, not food safety standard. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 163

164 This page is left intentionally blank 164 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

165 Annex 1-2: Summary of data for selection of the Base Cases The matrix below summarises previous data, no longer valid, used to prioritise the refrigeration products for further analysis in Task 4 of ENTR Lot 1. Table 1-56 shows the updated data as per the results of this study. These figures indicated that the products for further analysis as Base Cases, due to their significant energy saving potentials, should be: Service cabinets. Blast cabinets. Walk-in cold rooms. Remote condensing units. Industrial process chillers. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 165

166 Product ENTR Lot 1 Service Cabinets Blast Cabinets Walk-in cold rooms Dessert and beverage machines Industrial process chillers Water dispensers Product type EU-27 sales [units in 2008] EU-27 stock [units in 2008] Table 1-55: Market and energy consumption figures for products in the scope of ENTR Lot 1 EU-27 sales [units in 2020] EU-27 stock [units in 2020] Estimated average total energy consump. per product [kwh/year] Approximate lifetime (years of sales to replace stock) [years] Total stock energy consump. TWh/year (2008) Total stock energy consump. TWh/year freeze scenario (2020) Estimated average energy saving potential per product [% in 2020] Total stock energy consump. TWh/year with energy savings scenario (2020) Estimated EU- 27 savings in TWh/year in 2020 Remote ,47 1,63 25% 1,35 0,28 Plug-in ,20 14,67 33% 11,37 3,29 Total Remote ,46 11,62 21% 9,73 1,90 Plug-in ,46 11,62 33% 8,69 2,94 Total Remote ,74 6,38 31% 5,99 0,40 Remote + PCU* ,74 6,38 39% 5,80 0,58 Plug-in ,49 12,76 39% 11,62 1,15 Total ,98 1,08 17% 0,97 0,11 Packaged ,65 28,31 30% 26,68 1,63 Plant ,16 2,83 30% 2,67 0,16 Total Bottled water ,90 2,11 23% 1,79 0,32 Mains water ,48 0,53 23% 0,45 0,08 Total Ice-makers ,93 5,48 10% 5,10 0,38 TOTAL *Packaged condensing units (PCU) ,25 73,54 23% 63,38 10, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 January 2010

167 Table 1-56: Updated market and energy consumption figures for products in the scope of ENTR Lot 1 Product EU-27 sales EU-27 sales* EU-27 stock EU-27 stock* EU-27 sales EU-27 sales* [units in 2008] [units in 2008] [units in 2008] [units in 2008] [units in 2020] [units in 2020] ENTR Lot / / /2010 Service Cabinets 397, ,444 3,260,163 3,260, , ,230 Variation 0% 0% 0% Blast Cabinets 500, ,655 3,100,000 1,331, , ,155 Variation -65% -57% -60% Walk-in cold rooms 88,289 88,289 1,521,659 1,521,659 99,230 99,230 Variation 0% 0% 0% Industrial process chillers 4,302 6,441 87,226 80,929 4,604 8,105 Variation 50% -7% 76% *Packaged condensing units (PCU) 631, ,759 5,260,581 5,243, , ,614 Variation -5% 0% -22% Dessert and beverage machines 150,000 1,500, ,630 Water dispensers 277,778 2,500, ,500 Ice-makers 120, , ,081 Refrigeration compressors 253,000 1,771, ,076 Refrigeration condensors 50, ,200 39,316 * Weighted Base Case used. Weighted average considering market shares for products working at several temperature ranges Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 167

168 Product Table 1-56: Updated market and energy consumption figures for products in the scope of ENTR Lot 1 (continuation) Estimated average Stock Stock total energy EU-27 stock EU-27 stock Increase Increase consump. per [units in 2020] [units in 2020]* Factor Factor product * [kwh/year] Estimated average total energy consump. Per weighted product [kwh/year]* ENTR Lot / / /2010 Service Cabinets 3,621,615 3,621, ,500 2,900 Variation 0% 0% -36% Blast Cabinets 3,444,100 1,761, ,750 3,031 Variation -49% 26% -55% Walk-in cold rooms 1,690,370 1,690, ,100 12,155 Variation 0% 0% -20% Industrial process chillers 78, , , ,015 Variation 36% -23% -5% *Packaged condensing units (PCU) 5,839,245 6,301, ,359 40,688 Variation 8% 38% 82% Dessert and beverage machines 1,666, Water dispensers 2,777, Ice-makers 1,095, ,000 Refrigeration compressors 1,771, ,920 Refrigeration condensors 393, ,102 * Weighted Base Case used. Weighted average considering market shares for products working at several temperature ranges 168 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 January 2010

169 Product Table 1-56: Updated market and energy consumption figures for products in the scope of ENTR Lot 1 (continuation) Total stock Estimated EU-27 Estimated Total stock Total stock energy saving with average Task 7 LLCC energy energy consump. annual BAU 1% energy saving saving consump. consump. (freeze annual potential per potential [TWh/year in [TWh/year in scenario) improvment product [% in 2008] 2008]* [TWh/year in [TWh/year in 2020] 2020] 2020] Estimated EU- 27 savings with complete LLCC efficiency [TWh/year in 2020] ENTR Lot / / / / /2010 Service Cabinets 32% 44% Variation -36%** Blast Cabinets 27% 34% Variation -81%** Walk-in cold rooms 37% 46% Variation -20%** Industrial process chillers 30% 34% Variation -12%** *Packaged condensing units (PCU) 23% 35% Variation 81%** Dessert and beverage machines 17% Water dispensers 0% Ice-makers 10% Refrigeration compressors 5% Refrigeration condensors 3% TOTAL Variation 30% 11% 36% * Weighted Base Case used. Weighted average considering market shares for products working at several temperature ranges ** Difference in the total stock energy consumption differences are due to the change in stock and new estimates of the energy consumption per unit (related to the weighting methodology) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 169

170 Annex 1-3: Summary of data for minibars Minibars are small refrigerated cabinets (average volume 30 litres), typically used to store drinks and snacks, and which are used in applications where low noise levels are necessary for comfort reasons (e.g. hotels rooms). Noiseless but more energy consuming technologies such as absorption (and in a smaller proportion thermoelectric) refrigeration are typically used in these products in order to fit the noise restriction needs of these applications. Minibars were initially foreseen as a product to be included in the scope of this present study. However, this product s environmental performance is already being discussed in the framework of the Ecodesign Directive, in the context of the development of ecodesign requirements for domestic refrigerators and freezers. The draft regulation on possible implementing measures for household refrigerating appliances 137 presents requirements covering electric mains operated household refrigerating appliances including those sold for non-household use or for the refrigeration of items other than foodstuffs. In terms of specific ecodesign requirements, this draft regulation set the maximum annual energy consumptions in terms of Energy Efficiency Index (EEI) 138 value that refrigeration appliances shall fulfil. Proposed minimum EEI values depending on the time after the implementing measure has come into force are shown in Table Refrigeration technology Compressiontype Absorption-type and other-type Table 1-57 Minimum Energy Efficiency Index 138 EEI 138 after the implementing measure has come into force 1 July July July 2015 <55 <44 <42 <150 <125 <110 The previous explanatory note of the working document 139 also stated that the differentiation of the requirements for the compression and the absorption is considered necessary because the compressor-type appliances are inherently more energy efficient; however, the absorption-type and the thermoelectric-type appliances are significantly less energy efficient, but are noiseless. Generic ecodesign requirements are also included in the draft regulation: 137 Source: EC, Draft Commission Regulation Implementing Directive 2005/32/EC with regard to Household Refrigerating Appliances, Energy Efficiency Index EEI is equal to the energy consumption of an equipment over a 48 hours period subject to specified ambient conditions and prescribed number of doors Source: EC, Meeting of the tenth Consultation Forum, Working Document on a Possible Commission Regulation Implementing Directive 2005/32/EC with regard to Household Refrigerating Appliances, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

171 From 1 July 2010: For household refrigerating appliances, information shall be provided in the instruction booklet provided by manufacturers concerning: the combination of drawers, baskets and shelves that result in the most efficient use of energy for the appliance; and how to minimize the energy consumption of the household refrigerating appliance in the use-phase. From 1 July 2013: (a) The fast freezing facility, or any similar function achieved through modification of the thermostat settings, in freezers and freezer compartments, shall, once activated by the end-user according to the manufacturer s instructions, automatically revert to the previous normal storage temperature conditions after no more than 72 hours. This requirement does not apply to refrigerator-freezers with one thermostat and one compressor which are equipped with an electromechanical control board. (b) Refrigerator-freezers with one thermostat and one compressor which are equipped with an electronic control board and can be used in ambient temperatures below +16 C according to the manufacturer s instructions shall be such that any winter setting switch or similar function guaranteeing the correct frozen-food storage temperature is automatically operated according to the ambient temperature where the appliance is installed. (c) Household refrigerating appliances with a storage volume below 10 litres shall automatically enter in an operating condition with a power consumption of 0.00 Watt after no more than 1 hour when empty. The mere presence of a hard off switch shall not be considered sufficient to fulfil this requirement. The annual market of the electric absorption refrigeration appliances is about 250,000 to 300,000 units, and the market for thermoelectric appliances is smaller. As a comparison, there are about 18 million domestic compressor refrigerators. EN 732:1998 Relevance: Mini-bars The safety and noise standard EN 732:1998 Specifications for dedicated liquefied petroleum gas appliances Absorption refrigerators applies to absorption refrigerators for the technical characteristics, safety requirements, test methods and marking of absorption refrigerating appliances using commercial butane and propane (liquefied petroleum gases). As mentioned, minibars have been included in the scope of the development of implementing measures for household refrigerating appliances. Therefore, minibars will not be discussed further in this study. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 171

172 Annex 1-4: Summary of data for wine storage appliances Wine storage appliances can be used both in the residential and in the commercial sectors. However, as for minibars, this product s environmental performance is already being discussed in the framework of the Ecodesign Directive, in the context of the development of ecodesign requirements for domestic refrigerators and freezers. For this category of appliances, generic and specific ecodesign requirements have already been adopted: generic requirements: From 1 July 2010: For wine storage appliances, the following information shall be displayed in the instruction booklet provided by manufacturers: This appliance is intended to be used exclusively for the storage of wine. Specific requirements are described in Table 1-57 above. Wine storage appliances are therefore excluded from the scope of the present study. 172 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

173 This page is left intentionally blank Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 173

174 Annex 1-5: Summary of data for dessert and beverage machines General product definition This category refers to a range of products use to refrigerate, store, and dispense beverages or desserts for consumption. Most common applications are ice cream makers, milk-shake or slush machines and cold drink dispensers Existing product definitions According to the International Dictionary of Refrigeration 26, an ice-cream cabinet is a refrigerated cabinet for retail storage of ice-cream. The ice-cream freezer is an apparatus for freezing the cream mix into ice-cream. There are no other equipment definitions in the category of dessert and beverage machines in the dictionary Product description In all the applications mentioned above, the temperatures are kept low by a refrigeration process based on vapour-compression technology. Apart from the refrigeration process (already explained in ), these products include specific processes for each application: Ice cream makers: an ice cream maker has two functions; the mixture has to be cooled, and during this cooling process, the mixture has to be constantly churned to break up ice crystals that form and introduce some air to the mixture so that the resultant ice cream will have a smooth and creamy texture. Ice cream machines typically have an integral condensing unit (plug-in). The condenser can either be water cooled or air cooled. Milk-shake or slush machines: the range of units covered therefore have many differences based on e.g. the type of product going into a unit (e.g. milk, fruit based slush, yogurt), the type of product coming out (e.g. milkshake, slushy, frozen yogurt), the amount of product that will be drawn in a specific time period, the unit size, and cooling type. Cold drink dispensers (soda fountains): this product keeps cold drinks at low temperatures avoiding freezing and facilitating the serving process of beverages. According to preliminary analysis from main EU manufacturer s technical data sheets, dessert and beverage machines are mostly plug-in units working with aircooled condensers, and the electricity consumption of such machines ranges from 300 to 1000 kwh/year Functional unit and performance parameter The primary function of dessert and beverage machines is to produce, store and dispense a certain amount of frozen dessert or beverage. The primary 174 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

175 performance parameter can therefore be defined as the amount of energy used to produce a certain amount of frozen dessert or beverage in kwh/litre of product Dessert and beverage machine classification and preliminary scope for the study The preliminary classification for beverage and dessert machines is illustrated in Figure At this stage, no sufficient data is available to decide if a more refine classification based on the type of dessert or the type of beverage is necessary. This will be further assessed in Task 4. Plug-in Desserts Beverages Dessert and beverage machines Remote Desserts Beverages Figure 1-31: classification for dessert and beverage machines No performance testing standard has been identified for these appliances. Dessert and beverage machines are not within the scope of any particular MEPS or labelling scheme proposed in EU or in third countries. Dessert and beverage machines are excluded from the scope of the present study. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 175

176 Annex 1-6: Summary of data for water dispensers General product definition A water dispenser is a device that cools and dispenses drinking water. According to the International Dictionary of Refrigeration 140 a water dispenser is a factory-made unit in which drinking water is cooled by refrigeration, and can be dispensed by some form of valve control Existing product definitions USA/California Appliance Efficiency Program Under the California 2009 Appliance Efficiency Regulation 141, a water dispenser is defined as a factory-made assembly that mechanically cools and heats potable water and that dispenses the cooled or heated water by integral or remote means US Energy Star The Energy Star certification program covers bottled water dispensers which are defined as a freestanding device that consumes energy and dispenses water from removable 4- to 5-gallon plastic bottles commonly positioned on top of the unit Product description Water dispensers exist in several configurations: Mains-connected (see Figure 1-32 (a) and (b)). These devices dispense water directly from municipal water supply and are connected to water disposal systems to dispose of unused water. Bottled water dispenses (see Figure 1-32 (c)). In this case, water is supplied from bottles of water placed on the top of the unit. Water coolers are not connected to a water disposal system to dump excess water apart from a small basin to catch minor spills. Some water coolers include a second dispenser that delivers hot water. The heating unit is integrated to the water cooler. Moreover, water dispensers can be, standalone products, wall mounted, or split products where the dispensing mechanism is packaged but in a separate location from the refrigeration unit. This preliminary product description will be further detailed in Task International Institute of Refrigeration. International Dictionary of Refrigeration Source: Source: US Energy Star program requirements for water coolers Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

177 (a) (b) (c) Figure 1-32 Typical water dispensers Preliminary data shows that these products have electricity consumptions ranging from 300kWh/year to 1600kWh/year Functional unit and performance parameter The primary function of water coolers is to cool down and maintain water at appropriate dispensing temperature. The performance of water coolers can be measured by amount of energy required to fulfil this function. The primary performance parameter can therefore be defined by the energy consumption required to provide a certain amount of water at the appropriate dispensing temperatures. This refers to what the ENERGY STAR program defines as the standby energy consumption Water dispenser classification and water dispensers included in the scope A preliminary classification of water dispensers in provided in Figure Mains connected Plug-in Cold water Combined boiling water Bottled Mains connected Bottled Mains connected Water dispensers Split Cold water Combined boiling water Bottled Mains connected Bottled Mains connected Wall mounted Cold water Combined boiling water Bottled Mains connected Bottled Figure 1-33: Classification for water dispensers ARI (withdrawn, see ASHRAE ) Relevance: Drinking water dispensers 143 Source: Mark Ellis, Minimum Energy Performance Standards for Self-Contained Commercial Refrigeration, Prepared for the Australian Greenhouse Office, Final Draft Report, 2000 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 177

178 Then ARI Self Contained, Mechanically Refrigerated Drinking water Coolers establishes for Self-Contained, Mechanically-Refrigerated Drinking- Water Coolers: definitions; test requirements; rating requirements; minimum data requirements for Published Ratings; operating requirements; marking and nameplate data; and conformance conditions. This standard has been withdrawn and is now replaced by ASHRAE Standard ASHRAE Standard Relevance: Water dispenser The ASHRAE Standard (revised ) Methods of Testing for Rating Drinking-Water Coolers with Self-Contained Mechanical Refrigeration (ANSI approved) prescribes a method of testing for the cooling capacity and energy consumption of self-contained mechanically refrigerated drinking-water coolers. This 2008 revision updates the 2006 edition to provide the rating information that was lost when ARI Standard 1010 was withdrawn. The purposes of this standard are to establish the types of equipment to which the provisions of this standard apply, to define terms describing the equipment covered and terms related to testing, to specify types of instrumentation and test apparatus required in testing, to specify methods of procedure to be used when testing for rating, to specify a uniform method for calculation of results, and to specify data and results to be recorded. CAN/CSA-C (R2008) Relevance: Drinking water coolers The CAN/CSA-C (R2008) Energy Performance of Drinking Water Coolers deals with self-contained drinking water coolers, giving the energy performance requirements. It is applicable for those equipments whose capacity is up to 20mL/s. The standard provides measuring methods and maximum levels of energy consumption. This document does not apply to equipments intended for use on central circulating-type systems or employing remote type condensing units. There has not been identified any particular standard, for testing or estimating minimal energy performance for water dispensers in EU. However, there are several possible models to follow from third countries: Canadian regulation (CAN/CSA-C (R2008)) establishes the maximum energy use according to the litres dispensed in a period of time, and appears most suitable for the EU context, whilst USA voluntary programme (Energy Star) establishes the same parameter in maximal energy use per day. A MEPS proposal for chilled (and boiled) water dispensers commissioned by the National Appliance and Equipment Energy Efficiency Committee (NAEEEC) was released on October 26, In this proposal, associated MEPS levels for chilled and combined boiling and chilled water dispensers were set to be equivalent to the ENERGY STAR criteria. 178 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

179 ENERGY STAR Programme for bottled water coolers (Version ) This programme provides energy efficiency criteria for bottled water dispensers and refers to the ARI 1010:2002 Standard for Self-Contained Mechanically- Refrigerated Drinking-Water Coolers. It is estimated 144 that ENERGY STAR qualified water coolers use about half the energy compared to conventional models. Box 1-7 presents ENERGY STAR program qualifying products and specifications for bottled water coolers. Box 1-7: ENERGY STAR Programme for Bottled Water Coolers 145 Water dispensers are excluded from the scope of the present study. 144 ENERGY STAR: ENERGY STAR: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 179

180 Annex 1-7: Summary of data for ice-makers General product definition Ice-makers are machines used to produce ice. Some ice-makers also have a storage capacity, while others have a dispensing functionality. Typical applications include e.g. ice production and storage in food preparation and display (hostel, restaurants), for ice sales to customers, and for drinks in food retailing. According to the International Dictionary of Refrigeration 146, an ice-maker is a compact refrigeration unit designed to automatically produce comparatively small quantities of ice Existing product definitions California Energy Commission (CEC) The CEC defined ice makers as following: 147 Automatic commercial ice-maker means a factory-made assembly that is shipped in one or more packages that consists of a condensing unit and ice-making section operating as an integrated unit, that makes and harvests ice, and that may store or dispense ice. US Energy Star Current Energy Star requirements for commercial ice machines define this type of product as a factory-made assembly (not necessarily shipped in one package) consisting of a condensing unit and ice-making section operating as an integrated unit, with means for making and harvesting ice. The program further categorises ice machines into three sub-types: Product description Ice Making Head (IMH): A model with the ice-making mechanism and the condensing unit in a single package, but with a separate ice storage bin. Packaged condensing unit (PCU): A model in which the ice-making mechanism and condenser or condensing unit are in separate sections. Self-Contained (SCU): A model in which the ice-making mechanism and storage compartment are in an integral cabinet. An ice-maker consists of two major subsystems: the refrigeration system and water supply/circulation/purge system. Ice-makers typically use vapour compression refrigeration to produce the refrigeration needed for ice production. However at this stage no quantitative data for the EU market is available to assess the share of compression-based appliances. 146 International Institute of Refrigeration. International Dictionary of Refrigeration Source: California Energy Commission, Appliance Efficiency regulation, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

181 The ice production process in an ice-maker can be described as following: water circulated into a sump which typically contains % more water than necessary for the production of a batch of ice. the water is then circulated over the evaporator in a freezing chamber, releasing its heat to the refrigerant flowing inside the evaporator and the water cools down and freezes. During the vapour-compression refrigeration cycle, compressor, condenser fan (for air-cooled machines) and the water circulating pump are activated. when the proper batch weight has been reached, the ice-maker enters the harvest mode. According to a US study 148, most machines use hot-gas harvest, in which hot refrigerant vapour warms the evaporator and melts the ice, freeing it on the plate, and it can be assumed most EU ice-makers operate typically as such. Once free, the ice falls into the storage bin below. during the harvesting process, the water remaining in the sump is purged and fresh water is flushed to remove any impurities. water fills the sump and the ice production-cycle repeats. In some ice-makers, the freezing and harvest process take place simultaneously. Depending of the location of the condensing unit (i.e. compressor and condenser), and on the location of the storage bin, ice-makers are typically classified in three sub categories 149 which influence the components included in the ice-maker: ice-making head units (plug-in ice makers, no storage): standard ice-makers with the ice-making mechanism and the condensing unit in a single package, but with separate ice storage self-contained units (plug-in ice makers, with storage): models in which the ice-making mechanism and storage compartment are in an integral cabinet packaged condensing units (remote ice makers, without storage): splitsystem models in which the ice-making mechanism and the condensing unit or the condenser, are in separate sections. Moreover, each of these sub categories of ice-makers can operate continuously (continuous freeze and harvest of ice at the same time) or alternatively (alternate freezing and harvesting periods, also known as cube type, or batch ). About 80% 150 of ice-makers are estimated to have integral air-cooled condensers (plug-in). Other condenser configurations include ice-makers with integral watercooled condensers (i.e. plug-in refrigerating equipment), and remote air-cooled condensing units (i.e. remote refrigerating equipment). 148 Source: Arthur D. Little Inc, Energy Savings Potential for Commercial Refrigeration Equipment, US DOE, 1996 and MARK ELLIS & Associates, Self-Contained Commercial Refrigeration, Australian Greenhouse Office, 2000 and MARK ELLIS & Associates, Remote Commercial Refrigeration, Australian Greenhouse Office, Source: Classification used by US DoE Federal energy management program 150 Source: American Council for an Energy Efficient Economy - As a preliminary basis, similar situation is assumed in Europe as well Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 181

182 Preliminary estimates range the electricity consumption of ice-makers around 5,000kWh/year Functional unit and performance parameter The main functionality of ice-makers is to produce a certain amount of ice within a certain period of time (e.g. 24 hours). Some types of ice-makers also propose storage and /or dispensing function. The performance of an ice-maker can therefore be expressed as the amount of energy used to produce a certain amount of ice in kwh/kg of ice (i.e. primary functional parameter). Canadian efficiency standards not only deal with the energy consumption, but with the water use to produce 1kg of ice (including waste water and water used by the condensing unit). This parameter should be further taken into account in possible regulations. Drinking water requirements and in particular drinking water Directive requirements will also need particular attention for this product. For ice-makers using a remote condensing unit an approach similar to what is done in the ARI 820 standard for ice-makers (USA) 152 could be used. Alternatively, an approach similar to what is done for remote display cabinets (ISO 23953) could be used to include the energy consumption of the packaged condensing unit in the total electricity consumption of the ice maker. This will be further elaborated in Task Ice-maker classification and ice makers in the scope of the study California regulation on energy efficiency (CEC ) presents a simple classification for these equipments based on the physical configuration of the equipment related to the harvest rate 153. Table 1-58: US California State ice-makers classification Equipment type Type of cooling Harvest rate (kg/24h) Ice making head Water < 227 > 227 and < 652 > 652 Air < 204 > 204 Remote condensing (but not < 454 Air remote compressor) > 454 Remote condensing and < 934 Air compressor > 934 Self-contained Water < 91 > 91 Air < 80 > Source: Mark Ellis & Associates. Minimum Energy Performance Standards for Commercial Refrigeration Cabinets. EECA Energy efficiency and Conservation Authority, June For remote ice makers, the energy consumption is calculated based on a total power input which includes condenser fan power (source: ARI 820 standard) 153 California energy commission: REV1.PDF 182 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

183 Canadian standard (CAN/CSA-C742-08) features a very similar classification to the one presented by the California regulation. Nevertheless, the equipments are first classified into batch or continuous processes. Table 1-59: Canadian classification for ice-makers Process Batch Continuous Equipment type Ice making head Self-contained Remote condensing (but not remote compressor) Remote condensing and compressor All Type of cooling Water Air Water Air Air Air Air Water Harvest rate (kg/24h) < and < < < < < < < < A preliminary classification of ice-makers is proposed as illustrated in Figure Continuous Plug-in Ice-makers Water-cooled condenser Air-cooled condenser Batch Continuous Batch Continuous Remote Water-cooled condenser Air-cooled condenser Batch Continuous Batch AHRI Relevance: Ice-makers Figure 1-34: Classification of ice-makers The AHRI standard Performance Rating of Automatic Commercial Icemakers describes standard test methods for performance rating of Automatic Commercial Ice-Makers Scope: The scope of this standard covers the following Automatic Ice-Makers: Plug-in Model (model in which the ice-making mechanism and storage compartment are in an integral cabinet) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 183

184 Split System Ice-Maker (model in which the ice-making mechanism and condenser or condensing unit are in separate sections) Cubes Type Ice Maker (The word cube is not a reference to a specific shape or size. It is a method of distinguishing equipment that has alternate freezing and harvesting periods) Continuous Type Ice Maker Test Requirements: The tests required for this standard shall be conducted in accordance with ASHRAE Standard 29 (see ASHRAE standards). Rating Conditions: The conditions of test for Standard Ratings are as follows: Ambient temperature: F [+32.2 C] (For a Split System Ice-Maker, the condenser air inlet temperature shall be F [+32.2 C] with the indoor ambient temperature F [+32.2 C] Water inlet temperature: F [+21.1 C] Water inlet pressure: 30.0 ±3.0 psig [207 ±21.0 kpa] Rating Requirements: The Standard Ratings include: Ice Harvest Rate: the gross weight of ice harvested, stated in lb/24 h [kg/24 h], stated in multiples of 1. Condenser Water Use Rate: the amount of water used by the condensing unit (if water cooled), stated in gal/100 lb [L/45.0 kg] of ice, stated in multiples of 1. Potable Water Use Rate: the amount of potable water used in making ice, including Dump Water, stated in gal/100 lb [L/45.0 kg] of ice, stated in multiples of 0.1. Energy Consumption Rate: total energy input rate, stated in kwh/100 lb [kwh/45.0 kg] of ice stated in multiples of 0.1. For split system ice-makers, total power input includes condenser fan power only. Bin Theoretical Storage Capacity: for plug-in model ice-makers only, the theoretical storage capacity and the storage effectiveness of the ice storage bin shall be determined in accordance with ARI Standard 820. For these models, the internal volume is the volume calculated up to the intended shut-off level. The intended shut-off level is defined as the height of the thermostat bulb; the bottom of the curtain or the height of the electric eye, depending upon the mechanism used to shut off the icemaker. Ice Hardness Factor: for continuous type ice-makers only, the ice hardness factor is the latent heat capacity of ice harvested, Btu/lb [W/kg], divided by 92.9 W/kg [144 Btu/lb], multiplied by 100, %. ASHRAE Standard Relevance: Ice-makers The ASHRAE Standard (revised in 2005) Methods of Testing Automatic Ice makers (ANSI Approved) prescribes the methods of testing automatic ice makers. The automatic ice maker may comprise one or more sections for shipping purposes. This standard does not include automatic ice makers installed in 184 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

185 household refrigerators, combination refrigerator-freezers, and household freezers. CAN/CSA-C Relevance: Ice-makers The CAN/CSA-C standard Energy performance of automatic icemakers and ice storage bins applies to factory-made automatic icemakers (cube, flake, crushed, or fragmented ice in batches or in a continuous process) with a capacity not exceeding 1814 kg/day, measured at standard rating conditions. It specifies requirements and test procedures for energy and water consumption and storage effectiveness and applies to self-contained icemakers where the ice-making mechanism and storage compartment are integrated in one cabinet; and splitsystem icemakers that have the ice-making mechanism and condensing unit in separate sections Condensers can be air- or water-cooled (see ). AS/NZS :2008 Relevance: Ice-makers The Australian/New Zealand Standard AS/NZS :2008 Performance of commercial ice makers and ice storage bins - Part 1: Test methods for ice makers Environmental performance specifies methods of measuring the electrical power consumption of water and air-cooled commercial ice makers connected to a nominal 230 V mains electricity supply. This standard applies to batch-type and continuous ice makers that produce ice in irregular shapes, flakes, ribbons or wafers as well as uniformly shaped ice cubes where the finished product does not exceed approximately 100 g in weight. This standard is linked to the Minimum energy performance standard (MEPS) requirements AS/NZS :2008. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 185

186 Automatic Ice-Makers (CSA C742-08) 154 As of January 1, 2008, Canada has amended their Energy Efficiency Regulations to strengthen the minimum energy efficiency requirements for automatic ice-makers. The Canadian Standards Association test method CSA C742 Performance of Automatic Ice-Makers and Ice Storage Bins is used to test equipment and ensure compliance with the requirements of the Regulations. Automatic ice-makers manufactured on or after January 1, 2008 must meet the minimum efficiency levels as specified in the Table These values are equivalent to the requirements for the state of California that have been effective since January 1, Equipment Type Ice-making head Ice-making head Remote-condensing (but not remote compressor) Remote-condensing and remote compressor Self-contained Self-contained Table 1-60 : Minimum energy efficiency requirements for automatic icemakers 155 Type of Cooling water air air air water air Commercial Ice-makers Production of Ice (kg per 24 hours) < to < < < < < < Maximum Energy Use (kj per kg), (where H is the ice harvest rate in kg per 24 hours) (0.961 x H) (0.192 x H) (1.502 x H) (0.192 x H) (0.664 x H) (0.664 x H) (3.32 x H) (8.19 x H) Maximum Condenser Water Use (litres per kg), (if water-cooled) ( x H ) ( x H) In Australia, commercial ice-makers fall under the products that are currently proposed for regulation in the future (AS/NZS :2008: Environmental performance of ice-makers), these MEPS and associated test methods (AS/NZS :2008) are currently waiting for RIS approval 156 by the Australian Government. ENERGY STAR Programme for commercial ice machines 154 Canadian Office of Energy Efficiency: Canadian Office of Energy Efficiency: cfm?text=N&printview=N 156 Regulation Impact Statement (RIS) is required, under the Australian Government s requirements, when a regulatory proposal is likely to have significant impacts on business and individuals or the economy. 186 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

187 This programme provides energy efficiency criteria for commercial ice machines in reference to the AHRI standard of the Performance Rating of Automatic Commercial Ice Makers. Commercial ice machines that have earned the ENERGY STAR are on average 15% more energy-efficient and 10% more water-efficient than standard models. This programme excludes water cooled units and flake and nugget ice machines. Box 1-8 presents ENERGY STAR programme qualifying products and specifications for commercial ice machines. Box 1-8: ENERGY STAR Programme for commercial ice machines 157 AHRI Certification Program: automatic commercial ice-makers and icestorage bins 158 Scope: Automatic Commercial Ice-Makers consisting of a condensing unit and icemaking section operating as an integrated unit for making and harvesting ice in batches. A self-contained Ice-Maker is a single unit totally integrated in a cabinet. A Split-System Ice-Maker has its ice making mechanism and condenser or condensing unit in separate sections. Also included is the non-refrigerated ice- 157 ENERGY STAR: f 158 AHRI: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 187

188 storage bin (non-refrigerated compartment, factory-made assembly for the storage of ice). Reference standards: AHRI on the Performance Rating of Automatic Commercial Ice Makers and AHRI for Ice Storage Bins Certified Ratings: The following Certification Program ratings are verified by test at the Standard Rating Conditions: Ice Harvest Rate, lb/24 h [kg/24 h] Potable Water Use Rate, gal/100 lb of ice [L/45.0 kg of ice] Condenser Water Use Rate, gal/100 lb of ice [L/45.0 kg of ice] Energy Consumption Rate, kwh/100 lb of ice [kwh/45.0 kg of ice] Bin Theoretical Storage Capacity, lb [kg] (Self-Contained Models only) Theoretical Storage Capacity, lb [kg] Ice-makers are excluded from the scope of the present study. 188 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

189 This page is left intentionally blank Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 189

190 Annex 1-8: Other information Market Transformation Programme The Market Transformation Programme (MTP) was launched following a consultation paper issued by the Environment & Business Division, in October The MTP supports the development and implementation of UK Government policy on sustainable products. MTP s aim is to reduce the environmental impact of products across the product life cycle by: Collecting information. Building evidence of future environmental impacts. Working with industry and other stakeholders. The approach is to communicate and interpret Government policy objectives as a set of specific action plans, or road maps, looking ahead at least ten years, and to get buy-in from policy-makers and industry at UK, EU, and international levels. SPMP also supports policy delivery, in particular, by developing corresponding product ecodesign information (labels) and performance requirements (standards) to encourage innovation and competition. Scope: Domestic or commercial appliances including commercial refrigeration (liquid chillers, service cabinets, cold rooms, cellar cooling equipment, ice-making machines, refrigerated display cases, and refrigerated vending machines). Identification of saving potentials for commercial refrigeration In a 2006 report 159, MTP develops three standard scenarios to illustrate the potential impacts of the associate market transformation strategies: Reference scenario: without policy intervention Earliest Best Practice scenario: what would happen if everyone started buying the best available products Policy scenario: estimate of the likely effects of a program of policy measures Comparing these scenarios, savings potential for energy use of commercial refrigeration has been identified. The development of minimum energy performance standards covering full and part load could help to access a significant proportion of the identified savings potential. There is also great potential for savings through better service/maintenance and optimisation of present equipment and systems. Moreover, refrigerants have an additional impact due to their direct carbon emissions through leakages and disposal. The development of refrigerants with no 159 Sustainable Products 2006: Policy Analysis and Projections Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

191 ozone-depleting potential and little, or no, global warming potential offers the possibility of reducing direct carbon emissions. In the case of more efficient refrigerants, it will reduce energy consumption and hence indirect carbon emissions as well. Proposed actions: The proposed actions for commercial refrigeration are: Revise performance criteria and expand the product range for the Enhanced Capital Allowance (ECA) scheme to include display and service cabinets and reverse cycle liquid chillers (>100 kw). (Revision completed in 2008) Engage trade groups and key buyers in green procurement initiatives. Develop standard and performance benchmarks for part-load operation of liquid chillers. Part-load testing and seasonal efficiency ratings would be more representative of the real-life situation. They need to be considered as a potential criterion for ECA. Development of criteria/thresholds and implementation of the Ecodesign Directive for display cabinets, liquid chillers and vending machines. The figure below shows UK scenarios for service cabinet electricity consumption of new service cabinets sold or to be sold in the UK between 2000 and where: The reference projection takes into account underlying trends in markets and technologies and the estimated or implicit impacts of historical and current policy measures. It does not take into account the impact of policies which are still being developed and are not targeted at specific products. The intention is to revise these projections once it becomes clearer how these new policy measures will affect commercial refrigeration products. The Earliest Best Practice (EBP) projection shows what would happen if all new UK sales were based on the most resource efficient options, taking into account design and production cycles, but not taking account of price or other market barriers. The P1 projection sets a target level of ambition that the Government is proposing could be delivered at a low cost, taking into account such things as current UK and global performance benchmarks, economies of scale and the capacity of the supply chain to take coherent action to deliver more energy efficient products. 160 DEFRA: Policy Brief: Improving the energy performance of commercial refrigeration products July 2008 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 191

192 Figure 1-35: Indicative energy efficiency (EEI) for refrigerated service cabinets DEFRA: Policy Brief: Improving the energy performance of commercial refrigeration products July Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

193 This page is left intentionally blank Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 193

194 Glossary AEC Air-off temperature Air-on temperature Base Case BAT BAU BC Binary ice Blowing agent BNAT CH Combined model Commercial chilling service cabinets Commercial freezing service cabinets Commercial or industrial air-, watercooled refrigeration process chillers low temperature Annual energy consumption Temperature of the air blown off the evaporator (evaporating temperature) Temperature of ambient air blown onto the condenser An abstract construct representing the average product on the market Best available technology Business as usual Blast cabinet Binary ice is the mixture of a substance in solid state in micron size and the same substance in liquid state. In some cases, it requires of a depressant to avoid coagulation of the solid part. Normally the employed substance is water In foam production, blowing or foaming agents are chemicals that by changing of state during the foam production process, release gases able to change the configuration of resins (foam solid structure) Best not-yet-available technology Process chiller Refrigeration equipments able to work in chilling and freezing cycles. Refrigerated enclosure designed for the storage, but not the display, of chilled foodstuff, accessible via one or more doors and/or drawers, and which is able to store the foodstuff at a temperature down to a minimum of 0 C. Refrigerated enclosure designed for the storage, but not the display, of frozen foodstuff, accessible via one or more doors and/or drawers, that includes a compressor, condenser and evaporator, and which is able to store the foodstuff at a temperature below 0 C. Systems including at least compressor, condenser, expansion valve and evaporator, among other parts, designed to provide cooling capacity for a process or chambers. They are designed to provide outlet evaporator temperatures from -25 C to -8 C. 194 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

195 Commercial or industrial air-, watercooled refrigeration process chillers medium temperature Commercial or industrial remote aircooled chilling condensing units Commercial or industrial remote aircooled freezing condensing units COP Critical Point DEC Dew point temperature Door type Duty cycle EEI ESEER Freezing Functional unit Gastronorm (size) GWP HT Systems including at least compressor, condenser, expansion valve and evaporator, among other parts, designed to provide cooling capacity for a process or chambers. They are designed to provide outlet evaporator temperatures from -12 C to +3 C. Combination of one or more compressor, condensers or liquid receivers (when applicable) and the regularly furnished accessories, specifically designed to provide cooling to other equipment at -10 C evaporating temperature. Combination of one or more compressor, condensers or liquid receivers (when applicable) and the regularly furnished accessories, specifically designed to provide cooling to other equipment at -32 C evaporating temperature Coefficient of performance The temperature and pressure at which the liquid and gaseous phases of a pure stable substance become identical. Also called critical state Direct energy consumption - the energy consumed directly by the components contained with a product Temperature at which moisture condenses. Solid door / transparent door The proportion of time (in %) during which a component is on and drawing power (or the times a unit is switched under the operation of a thermostat) Energy efficiency index European Seasonal Energy Efficiency Ratio Cooling or maintenance of a space and the product contained therein to temperatures below 0 C The basis for comparison between similar products when performing lifecycle analysis (e.g. one unit of storage maintained at a specific temperature) It is the standard size for the tray/shelf of refrigeration equipments. It can be reference for trolleys or shelves. Global Warming Potential High temperature Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 195

196 Integral Isentropric Isentropic efficiency Lambda (λ) LLCC Load Load-line LT MEPS MT Net volume ODP OEM A product that integrates the condesing unit within the body of the equipment Ideal process with no change of entrophy of the system ratio of the product of the actual mass flow and the change in isentropic enthalpy across the compressor to the power input Thermal conductivity factor (λ = W/m.K) Least lifecycle cost The demand (in %) on a compressor's cooling capacity For each part of the cabinet, boundary surface consisting of one or several planes within which all test packages may be stored within the temperature limits of the actual temperature class Low temperature Minimum energy performance standards Medium temperature Adjusted internal volume, used to reflect space which can in practice be used to store goods Ozone Depleting Potential Original equipment manufacturer Operation temperature Temp of storage space (target temperature/operating temperature/application temperature) Packaged Pass through Performance parameter Plug-in Plug-in commercial blast chilling cabinet A product that has been manufactured and provided as a single piece of equipment Equipments similar to roll-in, but presenting two doors, one for the loading and the other one for the unloading. The means of comparing performance of similar products, using the functional unit and product consumption/impact (e.g. annual electricity consumption of product divided by number of functional units it provides) A product that operates after being plugged into the mains (i.e. no professional installation required) Equipment that includes compressor, condensor, evaporator and at least one fan able to cool down the temperature of the foodstuff from +70 C to +3 C in a short period of time, i.e. 90 minutes. The foodstuff is arranged in trays within the equipment or trolleys that 196 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

197 are taken into the equipment. Plug-in commercial blast chilling/freezing cabinet Plug-in commercial blast freezing cabinet Protocol R value Reach-in / cabinet REC Refrigeration Remote RCU Remote commercial blast chilling cabinet Remote commercial blast chilling/freezing cabinet Remote commercial blast freezing cabinet Equipment that includes compressor, condensor, evaporator and at least one fan able to chill or freeze the foodstuff from 70 C to +3 C and -18 C respectively in 90 or 240 minutes. The foodstuff is arranged in trays within the equipment or trolleys that are taken into the equipment. Equipment that includes compressor, condensor, evaporator and at least one fan able to freeze the temperature of the foodstuff from 70 C to -18 C in a short period of time, 240 minutes. The foodstuff is arranged in trays within the equipment or trolleys that are taken into the equipment. Specific door opening pattern used during testing to evaluate a product s performance under a standard Thermal resistance value (R = m 2.K/W) Refrigeration equipments where the user stands outside the appliance to load and unload the foodstuff. Refrigeration energy consumption - the energy consumed by the refrigeration system Cooling or maintenance of a space and the product contained therein to temperatures above 0 C A product with a remote condensing unit Remote condensing unit Equipment that includes compressor, evaporator and at least one fan. It is connected to a remote condensing unit. This equipment is able to cool down the temperature of the foodstuff from +70 C to +3 C in a short period of time, i.e. 90 minutes. The foodstuff is arranged in trays within the equipment or trolleys that are taken into the equipment. Equipment that includes compressor, evaporator and at least one fan. It is connected to a remote condensing unit. This equipment is able to chill or freeze the foodstuff from 70 C to +3 C and -18 C respectively in 90 or 240 minutes. The foodstuff is arranged in trays within the equipment or trolleys that are taken into the equipment. Equipment that includes compressor, evaporator and at least one fan. It is connected to a remote condensing unit. This equipment is able to freeze the temperature of the foodstuff from 70 C to -18 C in a short period of time, 240 minutes. The foodstuff is arranged in trays within the equipment or trolleys that are taken into the equipment. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1 197

198 Roll-in / trolley SC Split system Subcritical refrigeration Superheating TEC Testing m-package TEWI Transcritical Trigeneration Triple point U value US DOE Use pattern VEPS Vertical unit WICR Water-off Refrigerating equipments of foodstuff where trolleys are wheeledin. The load and discharge is done using the door. Service cabinet A refrigeration system that has been split - the evaporator is separate from the refrigeration system (terminology normally used for air-conditioning) The refrigeration cycles are entirely below the critical pressure point of the refrigerant Superheating is referred to the process of heating a substance over its boiling point. This is reached under specific pressure conditions. Total energy consumption; TEC = REC (refrigeration energy consumption) + DEC (direct energy consumption) for remote refrigeration systems; TEC = DEC for plug-in refrigeration systems Measurement packaged used in testing to replicate food, usually includes thermometer to measure temperature. Total equivalent warming impact Parts of the refrigeration cycle are above and other parts are below the critical pressure point of the refrigerant. CCHP (combined cooling, heating, and power generation) State where co-existence of liquid-, vapour- and solid-phase is possible. This phenomenon depends on the pressure and temperature Thermal conductance factor (U = W/m 2.K) United States Department of Energy The time a unit is switched 'on', providing cooling Voluntary efficiency performance standards Machine with a vertical design or layout. Walk-in cold room Temperature of water leaving a chiller 198 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 1

199 . European Commission DG ENTR Preparatory Study for Eco-design Requirements of EuPs [Contract N S ] Lot 1 Refrigerating and freezing equipment: Service cabinets, blast cabinets, walk-in cold rooms, industrial process chillers, water dispensers, ice-makers, dessert and beverage machines, minibars, wine storage appliances and packaged condensing units Task 2: Economic and market analysis Final report Contact BIO Intelligence Service S.A.S. Shailendra Mudgal Jonathan Bain +33 (0) shailendra.mudgal@biois.com jonathan.bain@biois.com

200 Project Team BIO Intelligence Service Mr. Shailendra Mudgal Mr. Benoît Tinetti Mr. Jonathan Bain Mr. Raul Cervantes Mr. Alvaro de Prado Trigo Disclaimer: The project team does not accept any liability for any direct or indirect damage resulting from the use of this report or its content. This report contains the results of research by the authors and is not to be perceived as the opinion of the European Commission. The European Commission is not responsible for any use that may be made of the information contained therein. 2 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

201 Contents 2. Task 2: Economic and market analysis Introduction Global market data Market trends Demand-side trends Food retailers and restaurants Centralised catering Eating habits Reliability, food safety and quality Population growth Kitchen size and user safety Technological trends Packaged equipment Natural refrigerants expected to increase replacement market Reduction of refrigerant charge Reduction of equipment footprint Reduction of noise levels Energy efficiency Voluntary measures System controls Compressor types Walk-in cold rooms and insulation EU market data EU-27 sales totals, growth rates and replacement sales Sales Annual growth rates Replacement sales EU-27 installed base (stock) Product life Product specific data Service cabinets Blast cabinets Walk-in cold rooms Process chillers Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 3

202 Remote condensing units EU market distribution structures and competition Maturity of the market Manufacturers of refrigerating equipment and refrigerants Market segmentation according to environmental and energy performance Refrigeration contractors (installers) Distribution channels Redesign cycles Climate conditions User expenditure base data Average consumer prices (ex. VAT) and manufacturer margins Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units Production cost structure and sector specific margin Installation costs Rates for running costs and disposal Running costs Disposal cost Interest and inflation rates Conclusions ANNEXES EU Production EU Trade Apparent EU consumption Methodological issues related to the use of PRODCOM data Prices of water dispensers Prices of dessert and beverage machines Prices of ice makers Dessert and beverage machines Water dispensers Ice-makers Market data for non-priority products Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

203 2. Task 2: Economic and market analysis 2.1. INTRODUCTION The objective of Task 2 is to assess the market, such as product stock and sales, market structure (e.g. supply chain, main players, manufacturing costs) and evolution (e.g. growth areas, trends in product design). Where possible, data for the EU-27 is described from the year 1990 until When assessing the stock and sales data, the Eurostat statistics, which rely on broad PRODCOM categories covering several products, do not provide a clear picture of the market (please see annex 2-1). Thus, alternative sources, including the literature and stakeholders, have been referenced. Possible eco-design measures should be consistent with the market structures and ongoing trends in product design. Market trends will also be an input for the subsequent tasks, such as improvement potential. Finally, practical data on consumer prices and rates is provided to be used later in the study in Life Cycle Cost (LCC) calculations. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 5

204 US $ million (sales) 2.2. GLOBAL MARKET DATA The commercial refrigeration market is very fragmented and produces equipment and components with a multitude of applications. Where possible, the market data is segmented by product group. Refined market segmentation, according to sub-categories of the product groups defined in Task 1, is also made. The annual worldwide sales of commercial refrigeration equipment are estimated to be around US$ 33,000 million (approx. 24,300 million 1 ) for the year For that same year, the projections estimate that the EU market will amount to US$ 8,230 million (approx. 6,051 millions), i.e. over a quarter of the global demand (see Figure 2-1). However, it is not clear whether other products covered by ENTR Lot 1, such as water dispensers, are included in the category parts and others, or not taken into consideration. 35,000 30,000 25,000 20,000 15,000 10,000 5, Other Asia/Pacific Japan China Africa/Mideast Eastern Europe Western Europe Latin America Canada & Mexico United States Figure 2-1: Worldwide sales of commercial refrigeration equipment 2 Western EU 3, along with the developed nations of North America and the Asia/Pacific region (i.e., Australia, Hong Kong, Japan, New Zealand, Singapore, South Korea), comprise mature markets for commercial refrigeration equipment. The US will remain the largest market in the world, as replacement demand continues to create sales opportunities The products covered under ENTR Lot 1 considered in these projections are estimated to represent 35% of the demand, amounting to approximately US$ 2,859 million (approximately 2,102 million) (see Figure 2-2). 1 1 = US$ Michael Deneen, World Commercial Refrigeration Equipment Industry Study, # Freedonia. World Commercial Refrigeration Equipment to Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

205 Parts and others (includes equipment covered by ENTR Lot 1) 35% Display Cases (TREN Lot 12) 17% Vending Machines (TREN Lot 12) 13% Ice-makers (ENTR Lot 1) 7% Service cabinets and walk-in cold rooms (i.e. ENTR Lot 1) 28% Figure 2-2: Worldwide sales of commercial refrigeration equipment by type 2 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 7

206 x MARKET TRENDS DEMAND-SIDE TRENDS Food retailers and restaurants Worldwide, the continued growth of the number of food retailers and restaurants will contribute to the growth of the commercial refrigeration market. The ongoing expansion of fast food chains will specifically benefit this sector, since these facilities utilise a wide range of commercial refrigeration equipment 3. At EU-27 level, growth of food retailers and restaurants is slow, which is in line with the low CAGR calculated in However, as in the UK, the cold storage capacity growth for the retail market in absolute terms is still estimated to be strong 4 (see Figure 2-3) Number of Restaurants; bars; canteens and catering (NACE H553 to H555) Number of food retailers (NACE G5211) Figure 2-3: EU-27 number of food retailers, restaurants, bars, canteens and catering facilities 5 This trend will in particular affect demand for service cabinets, blast cabinets, walk-in cold rooms and remote condensing units Centralised catering The use of large central catering establishments (sometimes referred to as central processing units) to cater for smaller satellite locations has been reported in the literature 6 and by stakeholders. This trend is likely to increase the consumption of refrigeration equipment for storage (equipment at smaller locations, retained and new equipment purchased for central processing sites), particularly blast cabinets 4 Defra. Policy Brief: Improving the energy performance of commercial refrigeration products EUROSTAT 6 BSRIA, French Market for Refrigeration, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

207 (to rapidly cool the large volumes of food produced to maintain quality and safety before storage), service cabinets and walk-in cold rooms Eating habits In Europe, the commercial refrigeration market trends are also driven by the increase in frozen food consumption 7 (more capacity is therefore required for larger quantities of products in the frozen segment, with approximately 12% of new frozen food products every 2 years). However, such factors may be stronger in commercial equipment used in the retail sector (e.g. refrigerated display cabinets). Stakeholders have also described the increased use of fresh food in catering. This requires the use of blast cabinets to pull down temperatures to maintain high levels of quality and hygiene of pre-cooked food (e.g. required when preparing large volumes of food in advance), and use of service cabinets and walk-in cold rooms for fresh food storage Reliability, food safety and quality Reliability is of high importance to many end-users (e.g. supermarkets to avoid break-down and loss of stock). Hence there is an inherent conservatism in the refrigeration market, through which it may be a struggle for new technologies to become established. Maintaining high levels of product quality is also an important driver in the market, both to achieve food safety standards and provide customer satisfaction. National legislation regarding food safety standards (see Task 1), such as the 1997 law in France (encouraging the use of blast cabinets in every professional kitchen) should also be considered. If similar legislation is drawn up in other countries within the EU, this could have an impact on sales, increasing the number of sold units in a short period of time Population growth Population growth in EU-27, with a CAGR for the period of +0.45% 5, could be an additional trend leading to a slight increase in commercial refrigeration equipment. However, population growth is not foreseen to be a strong driving factor Kitchen size and user safety It has been stated that there is a trend that kitchens are getting smaller, leading to higher demand for horizontal refrigeration. Refrigerators with either cupboards or drawers for local storage of both refrigerated and frozen products are used so that foodstuffs are close to hand in the kitchen. Due to faster access and a reduction of the risks associated with professional users bending down in front of horizontal doors in busy kitchens, sales of products with drawers may increase in the coming years 8. 7 Defra. Policy Brief: Improving the energy performance of commercial refrigeration products and BIO Intelligence Service. Lot 12 Preparatory Study, Final Report for DG TREN. December Source: Adande Refrigeration Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 9

208 TECHNOLOGICAL TRENDS The technical aspects of these trends will be discussed in more detail in Task Packaged equipment Increasing demand for packaged refrigeration products, integrating the refrigerant charge and more sophisticated controls, will require less skill to install and maintain, and could also reduce use costs through greater energy efficiency. Stakeholders mentioned this trend, due to the decline of refrigeration engineering skills in the market and ease of use, and consider that this could affect the condensing unit, process chiller and remote product market segments. A secondary benefit of packaged products is their reduced refrigerant charge compared to central refrigeration systems. One issue regarding alternative, low- GWP refrigerants is that they can have increased flammability and toxicity. Containing these refrigerants in equipment with higher standards of build quality (achieved in automated manufacturing environments) can be a means of reducing risk, and smaller refrigerant charges can be dispersed in place of a single large charge. Lastly, the importance of reliability for end-users (e.g. supermarkets to avoid break-down and loss of stock) may impact on this trend several dispersed packaged systems may be more desirable than a single central plant Natural refrigerants expected to increase replacement market The choice of the refrigerant is a major issue in the refrigeration industry. Refrigeration manufacturers are affected by the legal and regulatory actions in different countries as well as by international policy initiatives, as described in Task 1. Since January 2010, the use of virgin HCFCs in the maintenance and servicing of all equipment has meant a transition from HCFCs (mostly HCFC-22) to HFCs: R-404A and R-507A for low and medium temperature (LT and MT) levels, whereas R-134a is chosen for medium temperature low-capacity systems. A number of low-gwp HCs (hydrocarbons), such as R290 (propane) and R600a (isobutane), as well as ammonia and CO 2 systems of different refrigeration capacities, have also been installed in various countries in the last 10 years 9, although R600a is mostly used in small domestic applications 10. This refrigerant transition has caused the industry to adapt to the new properties of these replacement refrigerants and to work on system redesign to develop products that can operate with R-404A, R-507A, and R-134a but also with HCs and CO UNEP. Report by the Refrigeration, Air Conditioning and Heat Pumps Option Committee This report also states that the choices for replacement refrigerants are different in Europe, Japan and the US. In Japan, voluntary policy is undertaken and more than one third of the new equipment uses HFCs. R-404A is preferred for low temperature and R-407C is used for medium temperatures. In the US, HCFC-22 is still in use, even in new equipment but more and more systems use R-404A. 10 Paulo Vodianitskaia, Ed McInerney (CLA) TOC Refrigeration, AC and Heat Pumps UNEP Dialogue Decision XX/8 Geneva 14 July 2009 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

209 In the current market, refrigeration equipment based on synthetic refrigerants (HFCs) is usually cheaper than technology based on alternative refrigerants, due to mass production of these extended technologies. However, this is not always the case, and depending upon the type of the system and design approach taken, the costs can be similar or even lower. In applications where safety and reliability aspects are strictly controlled by standards, HCs are competitive and used due to their relatively safe and non-toxic characteristics. For example, just over 35% of current production of domestic refrigerators and freezers are equipped with HC refrigerants, primarily R600a 11. This percentage is close to 100% in the EU 12. Some stakeholders have increased sales of units using HCs in certain product categories, such as service cabinets, to as high as 29% 13, and the trend toward use of alternative refrigerants may increase with further legislation, design/safety improvements and consumer acceptance. Large-scale roll-out of refrigeration systems based on more environmentallyfriendly natural refrigerants such as ammonia and CO 2 has not yet occurred. However, the trend toward natural refrigerants is expected to drive the demand for compressors which are compatible with their utilisation. Already, leading compressor manufacturers have responded to the demand from the retail sector for more environmentally-friendly technologies with the addition of CO 2 -based compressors in their portfolio. Switching to new refrigerants not only depends on the availability of compatible compressors and other components but also on the global availability of refrigerants, and on the technical familiarity of technicians and engineers (i.e. refrigeration contractors). There are however some trade-offs to consider for the use of these refrigerants, such as performance in varying ambient conditions, toxicity and flammability. Some of these issues can be mitigated by the reduction of refrigerant charges Reduction of refrigerant charge New technologies such as mini-channel heat exchangers 14 are mainly aimed at reducing the refrigerant charge, and can be an important advantage for the use of HCs, ammonia and other refrigerants with safety issues. These technologies increase the heat exchanger surface by minimising the heat exchanger size, thus allowing a higher efficiency, a lower refrigerant charge and smaller footprint Reduction of equipment footprint Another trend is toward units with a smaller "footprint" (the physical space taken by the machinery at the location of use). New technology, such as mini-channel heat exchangers can be used to decrease products physical footprints (without 11 McInerney, E. et al. (2009) Task force deceision XX/8 report: Assessment of alternatives to HCFCs and HFCs and update of the TEAP 2005 supplement report data, UNEP Technology and Economic Assessment Panel 12 UNEP. TEAP 2010 progress report Volume 1. Assessment of HCFCs and environmentally sound alternatives. Scoping study on alternatives to HCFC refrigerants unter high ambient temperature conditions May Foster Refrigeration, Corporate Social Responsibility Report 09/10 14 Kandlikar, S G, A Roadmap for Implementing Minichannels in Refrigeration and Air-Conditioning Systems - Current Status and Future Directions; Heat Transfer Engineering, 28(12): , 2007) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 11

210 affecting storage volume), and slim-line versions of products can be purchased that do not conform to the Gastronorm dimensions (please see Task 1 for details) Reduction of noise levels Commercial refrigeration appliances are increasingly required by customers to reduce the noise level produced during operation, particularly in those products located indoors in common areas. For remote condensing units installed outdoors or in machinery rooms this problem is not so important and the footprint is the driver in design. Professional refrigeration products (covered by the Machinery Directive) are covered by regulation related to safety in terms of noise emission (acoustic pressure), which requires a different approach to that for domestic products 15. Compressor motors and fans are the parts in the commercial refrigeration appliances which produce the most noise. Both have been developed with new technologies such as scroll, screw or rotary compressors and variable speed drive motors that contribute to reducing the level of noise emitted by the product Energy efficiency Intelligent defrost systems and anti-sweat heaters, as well as variable capacity control systems and improved designs for compressors are being developed, along with various monitoring systems relying on sophisticated software packages (e.g. the introduction of microprocessor-based controls to reduce energy use 16 ). Demand for new and more efficient products is expected to further increase over the long term 17. Technological innovation in the area of commercial refrigeration energy efficiency also consists of improvements in materials (e.g. insulating materials) Voluntary measures As described in Task 1, EU voluntary programmes such as the EUROVENT and ASERCOM certification programmes, the UK ECA scheme, and national MEPS requirements in various third countries can be identified as trends setters toward improved efficiency of these products. They require manufacturers to either meet certain performance standards or provide information on the energy consumption of their products System controls The implementation of capacity controls and evaporating and condensing temperature controls in refrigeration equipment is allowing reductions in energy consumption. According to the manufacturers, this trend will increase in the following years. Variable capacity controls allow the machine to work at part load or full load conditions depending on the needs, thereby increasing efficiency and reducing 15 Source: Electrolux 16 Deneen, Michael A.,Gross, Andrew C. The global commercial refrigeration equipment market. (Focus on Industries and Markets) Frost & Sullivan. The European Refrigeration Compressors Market Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

211 energy consumption. Variable condensing pressure allows the condenser to work at different condensing temperatures depending on the ambient temperature, thus reducing the workload and energy consumption. These types of controls allow higher efficiencies to be achieved over the year in varying seasonal conditions Compressor types A shift is occurring in the commercial refrigeration market towards scroll compressors, especially in machines with medium to high cooling capacities. This trend is expected to strengthen in the following years. However, new developments are being applied to small hermetic reciprocating compressors, which achieve high efficiencies that make these compressors suitable for small commercial refrigeration machines Walk-in cold rooms and insulation Regarding walk-in cold rooms and stores, polystyrene/styrene is no longer used due to fire hazard. According to stakeholders, there are ongoing research initiatives by panel manufacturers to develop alternatives. Polyurethane (PUR) foam is standard in industry (approx 80 to 95%), and polyisocyanurate (PIR) foam is also used (5 to 20% - but it is though mainly for larger cold stores), and reportedly rare use of expanded polystyrene (XPS) or phenolic (PF) foam 18. For larger cold store manufacturers, the market is governed by panel manufacturers/foaming machine manufacturers. In general, market is limited in terms of innovation, due to small players and lack of resource to develop new technologies; it relies on developments in larger markets (e.g. components) Source: GR Scott, Assofoodtec (IT) 19 Discussed at EFCEM meeting on walk-in cold rooms, London, 12/10/2010. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 13

212 2.4. EU MARKET DATA EU-27 SALES TOTALS, GROWTH RATES AND REPLACEMENT SALES Data related to service cabinets, blast cabinets, walk-in cold rooms, industrial process chillers, ice makers, remote condensing units, and refrigeration compressors (other than the one included in plug-in commercial refrigeration equipment), is derived from various sources, including literature, TREN Lot 12 figures and feedback from stakeholders Sales As no robust public market data covering EU-27 were available, the EU-27 refrigeration equipment market was estimated on UK and French statistics published by UK MTP 20 and BSRIA 22. Sales data from the UK and France were used to extrapolate to the EU-27 level, assuming the UK market represents 13.5%, and the French market around 12.6%, of the total EU-27 market (this percentage estimate is based on expert estimates from major EU manufacturers collected during the TREN Lot 12 preparatory study 21 ) for service cabinets, walk-in cold rooms and process chillers. Blast cabinets were estimated through stakeholder comments and other sources, described below. BSRIA data 22 was also used as the basis for the calculation of remote condensing unit sales and stock. The data is presented in Table 2-1 and It is assumed that the Western EU market represents 85% of the total EU-27 market 2. However, the UK and French market may have a different segmentation or distribution per product category compared to the EU market as a whole (which will likely depend on national food consumption habits as well). Such an extrapolation by product category might thus be biased. Updated figures were obtained from the ENTR Lot 1 first stakeholder questionnaire 23 and individual stakeholder feedback. The figures for blast cabinets take into account the following information: BSRIA report on French Market for Refrigeration considers that blast equipment sales and installed base was similar to that of the service cabinets for year This could be explained by the French law that encourages establishments to pull down the temperature of foodstuffs in a certain period of time (French law of 29/09/1997) after being cooked. As result of this law, France is a very significant consumer of blast equipment. Also, France consumption of blast equipment is expected to be one of the highest in Europe when considering that the country has 15% of hotel and UK Defra statistics available at 21 Data collected during the TREN Lot 12 Preparatory Study on refrigerated display cabinets and vending machines, among major EU manufacturers - BIO Intelligence Service. Lot 12 Preparatory Study, Final Report for DG TREN. December BSRIA French Market for Refrigeration BIO Intelligence Service. First ENTR Lot 1 online questionnaire to stakeholders. Different versions of the questionnaire are available depending on the product category and can be downloaded from Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

213 restaurant establishments in Europe 24, after Spain and Italy only. This can lead to the conclusion that French market can represent around 15% of the total market of blast cabinets. According to Eurostat figures, France accounted for 26% of new hotel and restaurant establishments from 2003 to In particular, for the same years studied by the BSRIA report, France had the third highest growth in this sector. Considering the 5 top countries (66% of the total figure) with new establishments between 2003 and 2007, the approximate trend of growth if 2.15% per year. This trend is considered applicable for the EU for the coming years. Catering is considered a increasing consumer of large blast cabinets, leading to a slight increase in sales. However, these companies are likely to purchase fewer larger units than restaurants. Considering these aspects, the sales for France are estimated to represent 25% of the total European market. According to stakeholders, figures for blast cabinets might represent around 10% of sales for service cabinets in average in Europe. France presents an extreme ratio between blast and service cabinets (1:4). Bty contrast, Northern European markets seem to have only 1 blast cabinet per every 20 service cabinets. Nevertheless, based on the assumptions above, these figures are thought to be higher. The BSRIA document shows figures for the French market for process industrial chillers. However, it does not mention the operational temperature range. It has been mentioned by stakeholders (Daikin, 2010) that the market for low and medium temperature process chillers is between 10 to 20% of the total market for process chillers. The figures below take this assumption into consideration. Table 2-1 shows the updated figures for past, current and future EU-27 sales, including extrapolated estimates for 2025 sales of service cabinets, blast cabinets, walk-in cold rooms, industrial process chillers and remote condensing units. Data for other products can be found in the Annex. Table 2-1: Updated sales estimates for EU-27 Product type Units Service cabinets 313, , , , , , ,396 Blast cabinets 95, , , , , , ,310 Walk-in cold rooms 73,481 87,925 88,052 88,289 91,059 99, ,522 Industrial process chillers 1 3,491 5,644 6,364 6,441 6,918 8,105 8,949 Remote condenser units 2 766, , , , , , ,608 1 Packaged and plants 2 Commercial refrigeration only Figure 2-4 shows the evolution of sales from 1990 to 2025 of products covered by ENTR Lot 1. This shows a high number of remote condensing units and service 24 Eurostat: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 15

214 cabinets in the EU market, and a small share for industrial process chillers and blast cabinets. Figure 2-4: EU-27 refrigeration sales evolution from 1990 to Annual growth rates Based on the sales figures in Table 2-1, the compound annual growth rate (CAGR) has been estimated for the period. It is relatively low for all product categories (see Table 2-2), and highlights the slow annual growth rate for refrigeration equipment. This demonstrates that the market is not particularly dynamic (in general linked to food consumption and hence EU population), and that new products may take time to disperse into the installed base (stock). The economic crisis may have significantly affected growth recently (EU GDP decreased by 4.5% in 2009), but the continued population growth and recovery of the economy should lead to further growth. 16 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

215 Table 2-2: Calculated CAGR for the period Product category CAGR Service cabinets 0.91% Blast cabinets 2.15% Walk-in cold rooms 0.78% Industrial process chillers 1.80% Remote condensing units -1.13% Replacement sales The shares of the sales for replacement 25 shown below were calculated using data on stock and sales provided in Table 2-1. The calculations show that about 90% of the sales in almost all groups are for replacement of an existing unit (see Table 2-3), which seems reasonable. In the case of remote condensing units and walk-in cold rooms, the replacement sales are slightly lower, due to the particular characteristics of the products and the requirement for installation. Table 2-3: Estimated share of replacement sales in 2008 (EU-27) 2008 Product category Replacement sales Share of replacement (units) sales over total sales (%) Service cabinets 367, Blast cabinets 471, Walk-in cold rooms 74, Industrial process chillers 136, Remote condensing units 36, EU-27 INSTALLED BASE (STOCK) Past and future estimates of the installed base of refrigeration equipment were also calculated based on Defra statistics and extrapolated to the EU-27 level (again assuming that the UK market represents 13.5% of the total EU-27 market). Such estimates were supplemented by a market study 26 on bottled water dispensers, as well as responses from the industry to the first questionnaire 27. Initial figures were presented in the previous working documents (Figure 2-2) and updated data are presented in Table Replacement sales for the year n = sales (n) [stock (n)-stock (n-1)] 26 Zenith International. West Europe Water Coolers market July 30, BIO Intelligence Service. First ENTR Lot 1 online questionnaire to stakeholders. Different versions of the questionnaire are available depending on the product category and can be downloaded from Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 17

216 Table 2-4: Updated estimates of EU-27 stock current, past and future Product type Units Service cabinets 2,404,852 3,196,511 3,228,919 3,260,163 3,380,904 3,621,615 3,824,409 Blast cabinets 516,141 1,035,798 1,292,529 1,331,197 1,478,884 1,761,092 1,958,727 Walk-in cold rooms 1,122,444 1,491,948 1,507,075 1,521,659 1,578,022 1,690,370 1,785,024 Industrial process chillers 1 8,455 76,417 78,707 80,929 89, , ,282 Remote condenser units 2 3,688,270 5,048,537 5,147,339 5,243,301 5,618,759 6,301,534 6,682,502 1 Packaged and plants 2 Commercial refrigeration only Stock for blast cabinets, for which figures were unavailable in from UK MTP, has been calculated considering the lifetime of the equipment and the potential sales as expressed in Table 2-4. Figure 2-5 illustrates the stock evolution across different product categories covered by ENTR Lot 1 in the years Figure 2-5: EU-27 stock evolution according to product category PRODUCT LIFE The average product life is a useful information which can be used for the calculation of market data when either only stock or sales data is available by applying the formula in Based on existing data from literature, estimates have been made regarding the product lifetime for the refrigeration equipment included in ENTR Lot 1. Results show that the product lifetime varies between 6 and 20 years, depending on the product category. Details are presented in Table Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

217 Source Defra MTP 28 Table 2-5: Estimates of product lifetime Study ADL ME estimates 1 Study estimates 2 (stock/sales in 2008) Figure to be used in ENTR Lot 1 analysis Product type (years) Service cabinets 8 8 to Blast cabinets * to Walk-in cold 25** 18.5** 18 - rooms 8 to 10*** *** Industrial process chillers Remote condensing units - 8 to 12 (air cooled only) - 10 (air cooled only) * Assumed to be similar to service cabinets ** Insulated box *** Semi-hermetic compressor servicing refrigeration equipment - : No data available/found 11.5 (air cooled only) PRODUCT SPECIFIC DATA More detailed market data was found in the responses to the first stakeholder questionnaire 31 and through stakeholder feedback Service cabinets In the following table the different market sections for service cabinets are shown. It is divided by operation temperature, configuration of the equipment and location of the condensing unit. The percentage of each sub-classification stock is assumed to be comparable to the percentage of sales. The total figures for sales and stock are extrapolated to the EU-27 from UK MTP data, estimating that the UK market is 13.5% of the EU market. 28 Defra statistics available at 29 Arthur D. Little, Inc. Energy Savings Potential for Commercial Refrigeration Equipment, Final Report Prepared for US Department of Energy Mark Ellis and Associates. Self-contained Commercial Refrigeration. March BIO Intelligence Service. First ENTR Lot 1 online questionnaire to stakeholders. Different versions of the questionnaire are available depending on the product category and can be downloaded from Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 19

218 Table 2-6: Sales and stock of service cabinets in 2008 by technical characteristic Technology Sales Stock (units) (%) (units) (%) Refrigerators 275, ,259, Freezers 116, , Refrigerators-freezers 5, , TOTAL 397,443 3,260,163 Vertical 278, ,282, Horizontal 115, , Chest 3, ,602 1 TOTAL 397,444 3,260,163 Plug-in 389, ,194, Remote 7, ,203 2 TOTAL 397,444 3,260,163 1-door 255, ,093, (+) doors 142, ,166, TOTAL 397,444 3,260,163 - : No data available/found The sale shares per product type are shown in the table below. Table 2-7: Market share per equipment category based on data provided by the industry Configuration Vertical Horizontal Operation temperature Refrigerator Freezer Refrigerator/ freezer Refrigerator Freezer Refrigerator/ freezer Model type: door numbers (~net volume in L) Condensing unit location Approximate market proportion 1 (~400 to 600L) Integral 33.61% Remote 0.69% 2 (~1300L) Integral 14.41% Remote 0.29% 1 (~400 to 600L) Integral 13.45% Remote 0.27% 2 (~1300L) Integral 5.76% Remote 0.12% 1 (~400 to 600L) Integral 0.69% Remote 0.01% 2 (~1300L) Integral 0.69% Remote 0.01% 1 (~150L) Integral 9.95% Remote 0.20% 2+ (up to ~800L) Integral 9.95% Remote 0.20% 1 (~150L) Integral 4.26% Remote 0.09% 2+ (up to ~800L) Integral 4.26% Remote 0.09% 1 Integral 0.00% Remote 0.00% 2+ Integral 0.00% 20 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

219 Configuration Chest Operation temperature Refrigerator Freezer Refrigerator/ freezer Model type: door numbers (~net volume in L) Condensing unit location Approximate market proportion Remote 0.00% Integral 0.00% Remote 0.00% Integral 0.00% Remote 0.00% Integral 0.98% Remote 0.02% Integral 0.00% Remote 0.00% Integral 0.00% Remote 0.00% Integral 0.00% Remote 0.00% Stakeholders have estimated that products with drawers account for about 5 32 to % of the market for horizontal products Blast cabinets In the following table the different market sections for blast cabinets are shown. It is divided by operation temperature, configuration of the equipment, capacity for cabinets only, capacity for trolley/pass-through equipment (stakeholders have mentioned that the energy consumption of these two types of equipment is comparable) and location of the condensing unit. The percentage of each subclassification stock is assumed to be comparable to the percentage of sales Source: Adande Refrigeration 33 Source: Foster Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 21

220 Table 2-8: Sales of blast cabinets in 2008, by technical characteristic Type of equipment Sales Stock (units) (%) (units) (%) Refrigerator 15, ,808 9 Freezer 1, ,312 1 Refrigerators-freezers 156, ,198, TOTAL 173,655 1,331,197 Reach-in / cabinet 147, ,131, Trolley 17, , Pass-through 8, ,560 5 TOTAL 173,655 1,331,197 Small reach-in R (3 trays) 44, ,837 9 Medium reach-in R (5 to 10 trays) 73, , Large reach-in R (14-15 trays) 14, ,891 6 Extra-large reach-in R (20 trays) 14, ,576 5 TOTAL 147,607 1,131,517 Small roll-in + pass through T (up to 100kg) 15, , Medium roll-in + pass-through T ( kg) 7, , Large roll-in + pass-through T ( kg) 2, , TOTAL 26, ,680 Plug-in 133, ,118, Remote 39, , TOTAL 173,655 1,331,197 These figures are considered as an average of the EU market, and are based on comments from stakeholders. According to stakeholders, the market share of larger equipment is higher in northern EU countries. Also, in these countries, chilling-only machines present higher market proportion. The sale shares per product type are shown in the table below. Table 2-9: Market share per equipment category based on data provided by the industry Model Function Size Approximate market share (%) Small R 1.91 Chilling Medium R 4.21 Large R 0.77 Extra-large R 0.77 Small R 0.26 Reach-in Medium R 0.43 Freezing Large R 0.09 Extra-large R 0.09 Small R Chilling/Freezing* Medium R Large R Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

221 Model Function Size Approximate market share (%) Extra-large R 7.65 Small T 0.06 Chilling Medium T 0.03 Large T 0.02 Small T 0.06 Roll-in Freezing Medium T 0.03 Large T 0.01 Small T 5.88 Chilling/Freezing* Medium T 2.94 Large T 0.98 Small T 0.03 Chilling Medium T 0.01 Large T 0.01 Small T 0.03 Pass-through Freezing Medium T 0.02 Large T 0.01 Small T 2.94 Chilling/Freezing* Medium T 1.47 Large T 0.49 *User behaviour corresponds only to chilling cycles. Information found in brochures only available for freezing cycles Walk-in cold rooms In the following table the different market sections for walk-in cold rooms are shown. It is divided by size, operation temperature and refrigeration system type. The percentage of each sub-classification stock is assumed to be comparable to the percentage of sales. The total figures for sales and stock are extrapolated to the EU-27 from UK MTP data, estimating that the UK market is 13.5% of the EU market. In general the end user, even without expert knowledge, can install a factory-built product, as the refrigerant is pre-charged (in either a single-piece packaged refrigeration unit or integral configuration), and all that is required is construction of the enclosure for use and attachment of the refrigeration system as required. The customised product (i.e. customised) is designed and constructed by a refrigeration installer, the insulated box often attached to a remote refrigeration system configuration, which frequently requires installation of piping and charging of the refrigerant (operations needing specialist skills). Another differentiation between factory-built and customised is that factory-built products are of predetermined sizes and shapes, whereas customised products can be designed to fit customer footprint requirements. Walk-in cold room enclosure kits and insulation panels are often manufactured by different companies from those manufacturing refrigeration systems. Two walk-in cold rooms of the same dimensions and panel thicknesses and intended for the Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 23

222 same use may be equipped, by the end user, with two completely different refrigeration systems 34. Table 2-10: Sales and stock of walk-in cold rooms in 2008 by technical characteristic Technology Sales Stock (units) (%) (units) (%) Small 59, ,019, Medium 27, , Large 1, ,499 2 TOTAL 88,289 1,521,659 Refrigerators 60, ,049, Freezers 26, , Refrigerators-freezers 8, ,217 1 TOTAL 88,289 1,521,659 Factory-built 26, , Customised 52, , TOTAL 88,289 1,521,659 Packaged unit 40, , Remote condensing unit 35, , Remote plant 13, , TOTAL 88,289 1,521,659 The sale shares per product type are shown in the table below. Table 2-11: Market share per equipment category based on data provided by the industry Size Small (up to 20m3) Medium (20m3 to 100m3) Operation temperature Refrigerators Freezer Refrigerator / freezer Refrigerators Freezer Design Refrigeration system Approximate market proportion Factory-built Packaged 22.25% Packaged unit 2.22% Customised RCU 15.57% Remote plant 4.45% Factory-built Packaged 11.27% Packaged unit 1.13% Customised RCU 7.89% Remote plant 2.25% Factory-built Packaged 0.00% Packaged unit 0.00% Customised RCU 0.00% Remote plant 0.00% Factory-built Packaged 4.68% Packaged unit 1.87% Customised RCU 11.21% Remote plant 5.61% Factory-built Packaged 1.62% Customised Packaged unit 0.65% RCU 3.89% 34 Source : INCOLD 24 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

223 Size Large (100m3 to 400m3) Operation temperature Refrigerator / freezer Refrigerators Freezer Refrigerator / freezer Design Refrigeration system Approximate market proportion Remote plant 1.94% Factory-built Packaged 0.00% Packaged unit 0.00% Customised RCU 0.00% Remote plant 0.00% Factory-built Packaged 0.00% Packaged unit 0.00% Customised RCU 0.57% Remote plant 0.57% Factory-built Packaged 0.00% Packaged unit 0.00% Customised RCU 0.24% Remote plant 0.24% Factory-built Packaged 0.00% Packaged unit 0.00% Customised RCU 0.00% Remote plant 0.00% Process chillers In the following table the different market sections for process chillers are shown. It is divided by configuration, and the percentage of each sub-classification stock is assumed to be the same as that for sales. The total sales and stock are extrapolated to the EU-27 from UK MTP data and BSRIA data, estimating that the UK market is 13.5% of the EU market, while the French market represents around 12.6%. The proportion of low and medium temperature water-cooled and air-cooled equipment is assumed to be similar to the proportion of these two types of equipment for high temperature (HT) chillers, i.e. about 30% of the market is expected to be water-cooled. This also follows the market shares found for RCUs, in which water-cooled equipment is less than 10% of the total market. Table 2-12: Sales and stock of industrial process chillers in 2008 by technical characteristic Technology Sales Stock (units) (%) (units) (%) Packaged 5, , Field erected , TOTAL 5,856 80,929 MT (-12 C to +3 C) 3, , LT (-25 C to -8 C) 2, , TOTAL 5,856 80,929 Small (<100kW) 1, , Medium ( kW) 2, , Large ( kW) 1, , Extra-large (>1000kW) ,046 5 TOTAL 5,856 80,929 Air-cooled 4, , Water-cooled 1, , Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 25

224 Sales Stock Technology (units) (%) (units) (%) TOTAL 5,856 80,929 The sale shares per product type are shown in the table below Table 2-13: Market share per equipment category based on data provided by the industry Operation temperature Size Cooling system Market Low and Medium temp (%) Small Air cooled 13.5 Water cooled 3.4 MT Medium Air cooled 19.0 Water cooled 6.3 Large Air cooled 7.9 Water cooled 3.4 Extra-large Air cooled 1.7 Water cooled 1.1 Small Air cooled 10.5 Water cooled 2.6 LT Medium Air cooled 13.8 Water cooled 5.9 Large Air cooled 6.1 Water cooled 2.6 Extra-large Air cooled 1.3 Water cooled Remote condensing units The total figures for remote condensing units sales and stock are extrapolated to the EU-27 from BSRIA Report French Market for Refrigeration 35, considering the sales trend during the years and the forecast foreseen in the report for years as the trend until 2025; the ratio sales per capita as a still value; and the replacement sales per year being 84%. Table 2-14: Sales and stock of remote condensing units in 2008 Technology Sales Stock (units) (%) (units) (%) Packaged single compressor 569,771 95% 4,981,136 95% Packaged with multiple compressors 29,988 5% 262,165 5% TOTAL 599,759 5,243,301 Low temperature (-35 C) 119,952 20% 1,048,660 20% Medium temperature (-10 C) 479,807 80% 4,194,641 80% TOTAL 599,759 5,243,301 LT - Cooling capacity 0.2kW-20kW 113,954 95% 996,227 95% LT - Cooling capacity 20kW-50kW 4,798 4% 41,946 4% LT - Cooling capacity > 50kW 1,200 1% 10,487 1% MT - Cooling capacity 0.2kW-20kW 383,846 80% 3,355,713 80% 35 BSRIA French Market for Refrigeration Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

225 MT - Cooling capacity 20kW-50kW 71,971 15% 629,196 15% MT - Cooling capacity > 50kW 23,990 5% 209,732 5% TOTAL 599,759 5,243,301 LT reciprocating compressor 113,954 95% 996,227 95% LT scroll compressor 5,998 5% 52,433 5% LT screw compressor 0 0.0% 0 0.0% LT rotary compressor 0 0.0% 0 0.0% MT reciprocating compressor 431,826 90% 3,775,177 90% MT scroll compressor 47,981 10% 419,464 10% MT screw compressor 0 0.0% 0 0.0% MT rotary compressor 0 0.0% 0 0.0% TOTAL 599,759 5,243,301 According to information provided by stakeholders, the most common condensing units in the EU market are small condensing units with low cooling capacity (between 1-20kW) and medium evaporating temperature. Market shares in the EU per operating temperature range and cooling capacity range according to information provided by stakeholders are shown in the table above. The sale shares per product type are shown in Table 2-15 below, and the complete market split per classification is given in Annex 2-9. Table 2-15 Market share per equipment category based on data provided by the industry Cooling Evaporating Compressor Aproximate market Configuration capacity temp. ( C) type Proportion (kw) Packaged condensing unit with single compressor LT (-35 C) MT (-10 C) kw average: 5-7 kw kw average: 20 kw >50 kw average: 50kW kw average: 5-7 kw kw average: Hermetic reciprocating 17.1% Scroll 0.6% Screw 0.1% Rotary 0.1% Hermetic reciprocating 2.7% Scroll 0.1% Screw 0.9% Rotary 0.0% Hermetic reciprocating 0.9% Scroll 0.0% Screw 0.0% Rotary 0.0% Hermetic reciprocating 0.0% Scroll 5.5% Screw 0.3% Rotary 0.3% Hermetic reciprocating 10.3% Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 27

226 Configuration Packaged condensing unit with twin compressors or more Evaporating temp. ( C) LT (-35 C) MT (-10 C) Cooling capacity (kw) Compressor type Aproximate market Proportion 20 kw Scroll 1.0% Screw 0.0% Rotary 0.1% Hermetic >50 kw average: 50kW kw kw average: 20 kw >50 kw average: 50kW kw kw average: 20 kw >50 kw average: 50kW 3.4% reciprocating Scroll 0.3% Screw 0.0% Rotary 0.0% - 0.7% scroll 0.7% screw 0.1% scroll 0.2% screw 0.0% - 0.0% scroll 0.0% screw 0.2% scroll 0.9% screw 0.1% Remote condensing units using parallel compressors (2 or more) are around 5% of the market of remote condensing units, whereas remote condensing units with a single compressor are the 95% of the market. The remote condensing units working on low temperatures (evaporating temperature -35 C) are 15% of the market, while medium temperatures (evaporating temperature +10 C) are 60% of the market and high temperatures (air conditioning temperatures, out of the scope of the present preparatory study) are 25% of the market. The largest share of the market are remote condensing units with low cooling capacities, between 0.3 kw and 20 kw. These are the 80% of the market, being the ranges between 20 kw and 50 kw the 15% and the condensing units with cooling capacity over 50 kw the 5% of the market. The remote condensing units running reciprocating compressors are the most common in the market, being 95% of the market for low temperatures and 90% for medium temperatures. Scroll compressors in remote condensing units are 4% in low temperatures and 9% in medium temperatures and screw and rotary compressors are less than 1% of the market each type for both temperature ranges. Most of the compressor motors are on/off type (93% for reciprocating, 98% for scroll and screw and 90% for rotary), the rest being VSD motors and 2-speed motors. 28 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

227 2.5. EU MARKET DISTRIBUTION STRUCTURES AND COMPETITION MATURITY OF THE MARKET In Europe, the market is mature and saturated, making competition strong. Moreover, there are production overcapacities, intensifying price pressure due to Asian competition and the need to lower production costs in order to maintain profit margins. Additionally, the customer base is highly dispersed and relatively sensitive to price changes, and products are becoming more standardised. In response to these challenges, producers have restructured via mergers/acquisitions, and product line differentiation 36. Supermarkets and food stores usually require short payback times, around 2 or 3 years, and do not make high investments on refrigeration equipment 37. On the other hand, manufacturers also require a short payback time, and the competitive market does not allow great price differentiations. Therefore, implementing changes affecting the design of the product or the production methods is not desired by manufacturers if the investment is not quickly recovered. There is also a desire by supermarkets to keep maintenance costs to a minimum, which is a key issue for decision of the type of system, size and complexity. Economic and demographic forecasts indicate that the eastern European markets are likely to continue their current dynamic growth. The markets are growing at a faster rate than in western European countries, and even though the average prices are similar, competitiveness lead to slightly lower prices. The refrigeration market is linked to sectors such as beverages and retail, and it is inevitable that economic progress in these segments should lead to growth opportunities. The expendable income of eastern European customers has led to a rapid growth in the retail markets. The growth in commercial surfaces has stimulated the product sector market, including condensing units, compressors and other components. Access to EU markets has increased the general standard for consumer goods, creating a demand for newer and better-quality products, together with the need of comply with the EU legislation. EU markets, however, are extremely pricesensitive, and new economical product ranges attract more customers. 38 In Western Europe, a decrease in the total number of supermarkets in Germany has been noticed in recent years 39, and a similar situation can be supposed in the rest of the western European countries. In Southern and Eastern Europe there are more small food retail stores and fewer supermarkets, but the expectation is an evolution similar to the western European model, with more supermarkets and therefore less small food retail stores. This leads to a change in the refrigeration 36 International Institute of Refrigeration/Institut International du Froid (IIR/IIF). Refrigeration - Industry as a partner for sustainable development Navigant consulting, Energy saving potential and R&D opportunities for commercial refrigeration Frost & Sullivan, Central and East European Refrigeration Systems Market 39 UBA, Comparative assessment of the climate relevance of supermarket refrigeration systems and equipment Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 29

228 equipment market, moving towards bigger products purchased by bigger and more exigent companies. New, bigger supermarkets allow the design and installation of decentralized systems, using remote condensing units or compressor packs, usually with a higher energy efficiency than standalone machines. However, these systems have lower flexibility when remodelling work has to be carried out within the store. As an indicator, German supermarkets are remodelled approximately every seven years and rebuilt in intervals of 14 years MANUFACTURERS OF REFRIGERATING EQUIPMENT AND REFRIGERANTS According to the International Institute of Refrigeration 36 (IIR), organisations falling into the category of manufacturers of refrigerating equipment and refrigerants increasingly tend to be multinational corporations. Refrigerant manufacturers (which manufacture refrigerants, secondary refrigerants, lubricants, etc.) tend to be very large corporations due to the costly infrastructures required (liquefied gas, and particularly liquefied natural gas). Worldwide, this market is dominated by 15 to 20 very large companies. Component (compressors, mechanical and electronic controls, heat exchangers) manufacturers tend to be multinationals with manufacturing sites in various parts of the world but can also be small and medium-sized enterprises (SMEs). Manufacturers of specialised equipment (service cabinets, etc.) may be multinationals, but tend to be SMEs. They cover a broad company size range. However, at this stage, the share of SMEs in this sector and in each market segment is not known. Some larger manufacturers also provide installation and maintenance services. At global level, major players include United Technologies Corporation (UTC), Ingersoll-Rand, and Manitowoc /Enodis which are estimated to represent over 25% of the world market (in Euros) 36. At the EU-27 level, UTC, and Ingersoll-Rand seem to be the largest big players as well as other companies such as e.g. Arneg, Foster, Jordao, Norpe, Williams Refrigeration, Ice-O-matic, Hoshizaki, and EPTA 2. In Europe, a survey conducted by AREA 36 (Air conditioning and Refrigeration European Association) among national refrigeration associations in 12 countries (Belgium, Denmark, Finland, France, Germany, Greece, Hungary, the Netherlands, Norway, Spain, Sweden and the United Kingdom) reported 5,000 specialised firms in the commercial refrigeration sector, which employ 73,000 personnel for a total turnover of 20,000 million. Some manufacturers by product group are provided below. 30 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

229 Table 2-16: Manufacturers by product group (alphabetical order) Service cabinets Electrolux Foster GRAM Infrico Polaris Williams Refr. Blast cabinets Adande refrigeration Afinox Asskuhl Castel IMAC Electrolux Fagor Industrial Foster FRANKE GRAM Infrico IRINOX Isselbaecher SAGI Sanyo Walk-in cold rooms Kits and insulation Kingspan Smeva Criocabin INCOLD MISA Refr. Refrigeration systems Riedel Zanotti Whole product Electrolux Foster Coldrooms GRAM GR Scott Williams Refri. Viessmann Chillers Broad Carrier Cention Daikin Frigopol Friotherm Grasso Johnson Controls Lennox Mayekawa McQuay Robur Star refrigeration Titan Trane Thermax Yazaki York by Johnson Controls WITT Remote condensing units Bitzer Bock Daikin Danfoss Embraco / Aspera Emerson/Copeland Frascold Güntner Hubbard Tecumseh TEV United refrigeration MARKET SEGMENTATION ACCORDING TO ENVIRONMENTAL AND ENERGY PERFORMANCE For service cabinets and walk-in cold rooms, stakeholders have commented that the market is roughly divided into two tiers of product quality. Higher tier products incorporate new technologies and use high-quality components and materials, differentiating themselves in terms of performance and energy efficiency (and/or low environmental impact). The manufacturers of these high environmental quality products might also have a disposal (end-of-life) scheme in place as part of an environmental management framework 40, to ensure proper treatment of the equipment on disposal. This all leads to higher product prices and a lower tier of product types that are manufactured on a low-cost and low-price basis. While the higher tier products might be strongly branded and compete to be included in MS incentive schemes (UK ECA and Danish ETL which target the top 20% and 50% of the market respectively), the lower-tier products, a growing segment 41, are sold mainly via wholesalers under generic brand names. Manufacturers may be involved in producing products in both of these two tiers of quality. Stakeholders did however state that many of the lower-tier products were being manufactured in Asia, sometimes based on old designs created in the EU, and that this competition was driving down prices, increasingly competing on price rather than high environmental performance, and hence forcing EU manufacturers to compete in the same tier. Associated quality and lifetime of the lower-tier products could lead to issues such as lower lifetime and higher product energy consumption. 40 For example, ISO Source: Foster Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 31

230 In particular for walk-in cold rooms, there is a concern that insufficiently policed regulation may lead to independent contractors installing poorly constructed products, at a low price, as cost is currently the main driver for customer product choice. If any regulatory framework fails to enforce requirements adequately, these installers could under-cut responsible manufacturers by providing low-cost and poor-performing products. Manufacturers have absorbed cost of recent improvements (cam-locks; energy efficient motors; etc.), but a more efficient system costs more up-front, and manufacturers state that customers do not want this, some need very quick payback and many cannot afford more higher-cost equipment. Even larger end-users reportedly often choose products that fall apart after 5 years (and are not concerned about the environmental impact and energy cost) 42. Stakeholders commented that blast cabinet marketing is focused on food quality and safety. Energy consumption is not a primary concern for customers, who value the benefits of improved food preservation (e.g. retained flavour and moisture, and reduced bacterial growth) that rapid cooling allows. Process chillers are sold in smaller numbers, and used for more specific applications. These are predominantly high-value products that are designed in careful consideration of their application. Air-conditioning chillers (not included in the scope of ENTR Lot 1) are however more standardised products, and are covered by the EUROVENT and UK ECA voluntary schemes. Remote condensing units are sold in very high numbers and are relatively standardised products, with some differentiation over efficiency improvements to allow energy savings. According to stakeholder comments, the most sold products used to be the smallest, simplest and cheapest options, and energy or environmental performance is not an important factor in the purchasing decision. However, these products are covered by the UK ECA, with minimum COP requirements REFRIGERATION CONTRACTORS (INSTALLERS) This group comprises many smaller businesses 43, employing up to 20 people. Refrigeration contractors play a vital role in ensuring the highest performance for the refrigeration equipment and reducing refrigerant direct emissions. They are responsible for the correct installation of the equipment, for maintenance according to good practice and for disposal at the end of the life cycle, again in compliance with good practice (see later Task 3). Contractors also play a key role as end-user advisers. Third party contractors are usually used to procure, supply and install commercial refrigeration equipment. 4 Manufacturers of commercial refrigeration equipment often partner with refrigeration contractors who provide installation and maintenance services for the products they sell. 42 Discussed at EFCEM meeting on walk-in cold rooms, London, 12/10/ International Institute of Refrigeration/Institut International du Froid (IIR/IIF). Refrigeration - 32 Industry as a partner for sustainable development Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

231 DISTRIBUTION CHANNELS Refrigeration equipment is distributed in five different ways (see Figure 2-11), by: utilising the manufacturer s own sales staff to sell directly to the enduser (channel 1); working through regional sales offices or manufacturers representatives to sell equipment to independent distributors (equipment dealers, distributors, agents, brokers, etc.) (channel 2); working through installers (i.e. mechanical contractors) who will sell it to the end-user (channel 3); working through regional sales offices or manufacturers representatives to sell equipment to independent distributors (equipment dealers, distributors, agents, brokers, etc.), who then sell the equipment to installers (i.e. mechanical contractors) who will sell it to the end-user (channel 4); selling to large food and beverage companies who then give their appliances for free or rent them to end-users who in return will sell their products (could be the case for e.g. ice machines, or beverage and dessert machines) (channel 5). Manufacturer (1) (2) (3) (4) (5) Distributor Installer Distributor Installer Food and Beverage company End-user Figure 2-6: Distribution channels Because of the highly fragmented industry and diverse factors affecting end-users needs, the most common distribution channel is from manufacturer to distributor to end-user (channel 2 in Figure 2-6). The distributor is the interface between the manufacturer and the customers. However, large chains often employ a contractor or an engineer to specify their needs and to buy equipment directly from the manufacturers 44. For service cabinets, it is estimated that the majority are sold 44 American Council for Energy Efficient Economy. Packaged Commercial Refrigeration Equipment: A Briefing Report for Program Planners and Implementers, ACEEE Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 33

232 through channels 1 (70%) and 2 (30%) in proportions similar to display cabinets 45.. For products requiring installation by professionals, such as remote condensing units, the main share of the sales is distributed by independent distributors (i.e. wholesalers) and installers, as shown in Table Table 2-17: EU-27 share of product sold through various distribution channels in 2008 Product type Service cabinets Blast cabinets Walk-in cold rooms Industrial process chillers Remote condensing units Channel 1 (directly to end-user) (%) - : No data available/found Channel 2 (via independent distributor etc.) (%) Channel 3 (via independent installer etc.) (%) Channel 4 (via mechanical contractors) (%) Channel 5 (via food industries) (%) REDESIGN CYCLES The redesign cycle is defined as the time from making the decision to change the design to the point when only new redesign products are sold, and a return on investment has begun to be made. The redesigning cycles for different product categories are presented in the table below. Data was obtained from the responses from the industry to the 1 st questionnaire 46. Table 2-18: Redesign cycles Product Redesign cycle (months) Service cabinets 25 Blast cabinets 10 Walk-in cold rooms - Industrial process chillers 42 Packaged condensing units 42 - : No data available/found BIO Intelligence Service. Lot 12 Preparatory Study, Final Report for DG TREN. December BIO Intelligence Service. First ENTR Lot 1 online questionnaire to stakeholders. Different versions of the questionnaire are available depending on the product category and can be downloaded from Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

233 CLIMATE CONDITIONS Climate conditions have importance in the refrigeration systems and energy consumption, since the performance of refrigeration products is often closely linked to ambient temperature. There are a variety of climatic zones in the EU-27, from the warm and dry Mediterranean coasts to the northern areas. Performance of commercial refrigeration equipment, as well as technologies appropriate can vary for these different climatic conditions. This is the case of the selection of the refrigerant, i.e. carbon dioxide is a commonly used in Nordic countries where cold ambient temperatures allow a high efficiency, whereas in warmer areas such as Southern Europe the efficiency of this refrigerant is very poor. Evaporative cooling technology for condensers is also closely linked to dry and warm climates, and its efficiency is also lower in dry and cold ambient conditions. Central Europe has cold winters with daily average maximum temperatures from 2 C in January to 25 C in July. The wettest months on average are July (84 mm) August (64 mm) and September (99 mm). Southern Europe has a warm dry winter. Daily average maximum temperatures vary from 7 C to 17 C. In the summer, daytime maximum average temperatures reach C Daily average maximum temperatures in Eastern Europe range from 1 C in January to 28 C in July. June (121 mm), July (96 mm) and May (72 mm) are the wettest months on average Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 35

234 2.6. USER EXPENDITURE BASE DATA AVERAGE CONSUMER PRICES (EX. VAT) AND MANUFACTURER MARGINS The consumer prices described in this section are the product list prices, and exclude VAT. However, the literature 48 and stakeholders state that list price is often significantly higher than the final sale price, with reductions of around 40% of the list price being common, and prices varying further, depending on factors such as volume of units to be purchased Service cabinets The average selling prices in for service cabinets range between 850 and over 3,000; depending on the size, operating temperature, and the exterior of the cabinet (i.e. stainless steel or white). 49 Typically, a stainless steel exterior will be more expensive than an equivalent model with a white exterior. Table 2-19 details the price ranges according to the type of service cabinet. A US study 50 estimated the price of a freezer service cabinet at around US$ 2,200 (approx. 1,620) for a volume of 24ft 3 (approx. 680 litres), and the price of a refrigerated service cabinet at US$ 2,500 (approx. 1,835) for a volume of 48ft 3 (approx. 1,360 litres). Table 2-19: Average prices for service cabinets (2009) Net storage volume, V (litres) V < < V <600 V >600 Description Average selling price ( ) Refrigerator 850 1,300 Freezer 1,000 1,400 Refrigerator 1,000 2,000 Freezer 1,400 2,500 Refrigerator 1,500 3,000 Freezer 1,500 3, BSRIA French Market for Refrigeration catalogue data 50 Arthur D. Little, Inc. Energy Savings Potential for Commercial Refrigeration Equipment, Final Report Prepared for US Department of Energy Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

235 Blast cabinets The typical price range for a blast cabinet is between 2,000 and 20,000 depending on the size. Table 2-20 details the price ranges according to the type of blast cabinets. Number of trays (GN 1/1) Table 2-20: Average prices for blast cabinets (2009) Approximate capacity of the equipment (kg) (trolleys) Walk-in cold rooms Description Refrigerator and/or freezer Refrigerator and/or freezer Refrigerator and/or freezer Average selling price ( ) 2,000 5,000 5,000 15,000 10,000 30,000 The typical price range for walk-in cold room sold as a factory assembled product is estimated at between 1,000 and 9,000 depending on the size. The price for the average walk-in cold room is about 8,800 (ex VAT) according to stakeholders. Table 2-21 details the price ranges according to the storage volume. Some stakeholders have stated that these figures may be high 51. Table 2-21: Average prices for factory assembled walk-in cold rooms (2009) Size Storage volume (m 3 ) Approximate price ranges ( ) ex VAT Small Up to 20 2,000 7,000 Medium 20 to 100 7,000 N/A Large 100 to 400 N/A Average ,800 N/A: data not found Process chillers From stakeholders comments, the price for the end-user is between 200 and 250 per kw of cooling capacity. This price includes manufacturing, installation, and training (if required). According to stakeholders, the estimated price for an average (270kW cooling capacity) process chiller is 60,000, where 15% VAT is not included. According to stakeholders, the increase in price between production cost and consumer price (including installation) is about 100% Remote condensing units An estimate of the price of remote condensing units based on responses to the 1 st questionnaire 53 shows that the selling price of such products is very high, between 51 Source: Viessmann 52 Defra MTP, based on an evaluation of the UK market Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 37

236 1,000 and 20,000. The distribution channels also influence the price, with usual price discounts being up to 50%-60% for big retailers or installers. The installation costs depend on the product, the installer and the country, and can be up to 20% of the total cost of the product. The public price of the product varies depending on the cooling capacity of the condensing unit, the number and size of the compressors, the technology used in the compressor, the housing, insulations, etc. As stated in , the typical remote condensing unit has between 5-7kW of cooling capacity for medium temperature (evaporation temperature -10 C), a single hermetic reciprocating compressor, and uses R404a as refrigerant. The average price of a product with these characteristics is around 4,500. Remote condensing units working at low evaporating temperatures are 20%-25% more expensive than remote condensing units with the same cooling capacity working at medium evaporating temperatures. On the other hand, higher cooling capacities mean higher prices in all the temperature ranges and compressor technologies. Regarding compressor types, reciprocating technology is the cheapest, being scroll and rotary 50% more expensive and screw around 55% more expensive than reciprocating. Variable speed drive technology for compressor motors increments the price in 50% over on/off technology in all types of compressors, whereas 2 speed technology is 20% more expensive than on/off PRODUCTION COST STRUCTURE AND SECTOR SPECIFIC MARGIN The production cost is the sum of the different costs due to direct labour, direct material, and overheads (including investment depreciation). Other nonproduction cost elements include selling, marketing, general and administrative, research and development, and interest. No robust data was found in existing literature to determine the proportion of each of these costs. In USA, the DoE estimates the manufacturer mark-up value to be a factor of According to information provided by stakeholders, the estimated margin for the equipment considered within the scope is: Table 2-22: Estimated margin per product Equipment Cost Approximate margin (%) * Service cabinets - 40 to 60 Blast cabinets - 40 to 60 ** BIO Intelligence Service. First ENTR Lot 1 online questionnaire to stakeholders. Different versions of the questionnaire are available depending on the product category and can be downloaded from 54 US DoE. Commercial Refrigeration Equipment ANOPR Technical Support Document, Chapter www1.eere.energy.gov/buildings/appliance_standards/commercial/pdfs/cre_nopr_tsd_chp_5.pdf Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

237 Equipment Cost Approximate margin (%) * Walk-in cold rooms - 10 Chillers /kw 100 Remote condensing units 1,000 20,000 /unit 100 to 300 *** * Ratio between cost of product and end-user price ** Margin increases with the equipment size. The range of margin refers to the price set by the manufacturer in brochures. Retailer price might not be the same (not business to business equipment) *** Includes installation costs: vary with the size of the system - : No data available/found INSTALLATION COSTS There is no significant installation cost for plug-in products. Remote appliances however need to be linked to a refrigeration system which supplies the appliance with refrigeration energy. The installation costs only consider the labour costs incurred, all material costs involved during installation will not be included, due to their being part of the refrigeration system costs. It is estimated at 10 % of the product cost based on the results for remote refrigerated display cabinets 45 and assuming installation costs are similar across remote refrigeration products. According to stakeholders, the installation cost for chillers is around 30% of the end-user cost. For split units the cost will be higher. A previous US study 55 estimates the installation costs for an ice-maker to be around US$ 300 (approx. 220). Service cabinets* Blast cabinets* Table 2-23: Installation costs by product Product Walk-in cold rooms* Cost (% product price) 10 (remote) 1 (plug-in) 10 (remote) 1 (plug-in) 10 (remote) 1 (plug-in) Industrial process chillers 30 Packaged condensing units* 10 - : No data available/found *: Estimate 55 Arthur D. Little, Inc. Energy Savings Potential for Commercial Refrigeration Equipment, Final Report Prepared for US Department of Energy Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 39

238 RATES FOR RUNNING COSTS AND DISPOSAL Running costs The significant running costs of refrigeration equipment are the electricity costs, the repair and maintenance costs, and the installation costs. Electricity costs Electricity prices for industry in Member States (MS), as of June 2008, are presented in Table These rates will be used in a Life Cycle Cost (LCC) calculation at a later stage in the study (Task 4). As demonstrated in the table, different electricity rates apply depending on annual energy consumption. Table 2-24 Electricity prices (first semester 2008) for industry depending on consumption 56 Electricity cost / kwh with taxes Industrial consumer IA Consump. < 20 MWh Industrial consumer IB 20 MWh < Consump. < 500 MWh Industrial consumer IC 500 MWh < Consump. < MWh Industrial consumer ID MWh < Consump. < MWh Industrial consumer IE MWh < Consump. < MWh Industrial consumer IF MWh < Consump. < MWh Austria Belgium Bulgaria Croatia Cyprus Czech Republic Denmark Estonia Finland France Germany Greece Hungary Ireland Italy Latvia Lithuania Luxembour g Malta Netherland s Norway EUROSTAT 40 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

239 Electricity cost / kwh with taxes Industrial consumer IA Consump. < 20 MWh Industrial consumer IB 20 MWh < Consump. < 500 MWh Industrial consumer IC 500 MWh < Consump. < MWh Industrial consumer ID MWh < Consump. < MWh Industrial consumer IE MWh < Consump. < MWh Industrial consumer IF MWh < Consump. < MWh Poland Portugal Romania Slovakia Slovenia Spain Sweden United Kingdom Average EU-27 - : No data available/found Repair and maintenance cost In the Energy Star LCC calculation tool, the maintenance cost for refrigeration and freezing appliances is negligible and fixed to zero. Assuming similar maintenance costs across all refrigeration equipment, during the whole product life they comprise about 7 % of the Life Cycle Cost. 45 According to the responses to the 1 st stakeholder questionnaire 57, repair as well as maintenance costs for blast refrigeration and freezers are around 500 during the life of the product. For service cabinets, blast refrigeration and freezers, industrial process chillers, as well as packaged condensing units, leak tests are required when there is more than 3kg of HFC refrigerant in the product. Usually it is advised to have from 2 to 4 inspections per year which includes checks of pressure switches, replacing door seals and controllers. It has been mentioned that maintenance actions for process chillers occur on a two-year basis. The cost of this maintenance is around 4% of the initial cost 58 for high temperature equipment, this figure could be more for low and medium temperature, since the components are less commonly produced Disposal cost Refrigeration equipment is often renewed before reaching the end of its life, and is sold in the second-hand market (exported to Africa, Asia, or Eastern Europe) or sold to scrap metal dealers, implying a source of income. 57 BIO Intelligence Service. First ENTR Lot 1 online questionnaire to stakeholders. Different versions of the questionnaire are available depending on the product category and can be downloaded from 58 Lot 6: Air-conditioning and ventilation systems. Draft Task Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 41

240 A small fraction of the products however (mostly plug-ins) are treated at household refrigeration products recycling plants. Less than 1% of the appliances found in these plants are commercial equipment 45. When disposed of in refrigerator recycling plants, the disposal costs depend on the weight and the volume of the commercial refrigeration equipment. In EU-27 Member States, this disposal cost varies between 60 and 250 per ton of equipment depending on many local factors such as electricity rates and staff wages 59. The recovery of 500g of refrigerant liquid costs approximately 4 and recycling plants typically try to recycle the other material such as metal (e.g. steel, copper, aluminium). Stakeholders have commented that refrigeration process chillers are sold for recycling at almost 100%; the only parts that not recycled are electronic and electrical components. A 4MW equipment can generate a profit of 5,000 to 10,000 at the end of its useful life in this way. In general, the refrigerant charge is 200 to 250g per kw of cooling capacity; this refrigerant must be collected as for the other equipment within the scope Interest and inflation rates The following table shows the annual average inflation rate in 2008 for Member States of EU-27 and inflation and long term interest rates for 2007 as published by Eurostat. Table 2-25: Interest and inflation rates for EU-27 Location 2008 Average Inflation rates % 2007 Long term Interest rates % Austria Belgium Bulgaria Cyprus Czech Republic Denmark Estonia Finland France Germany Greece Hungary Ireland Italy Latvia Lithuania Luxembourg Malta Source : Interview with Mr. Christoph Becker RAL Quality Assurance Association for the Demanufacture of Refrigeration Equipment Containing CFCs Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

241 Location 2008 Average Inflation rates % 2007 Long term Interest rates % Netherlands Poland Portugal Romania Slovakia Slovenia Spain Sweden United Kingdom EU : No data available/found Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 43

242 2.7. CONCLUSIONS In the absence of a single source for comprehensive market data, current sales and stock of refrigeration equipment have been derived from a variety of sources. The accuracy of the figures presented may be challenged; they clearly show, however, that the yearly sales of the products are higher than the volume threshold set in the Eco-design Directive (apart from industrial process chillers and blast cabinets). Existing data also highlights the slow growth of the refrigeration products market, with low CAGR, a high proportion of replacement sales, long redesign cycles, and long product lifetimes. This could limit rapid integration of any new technologies introduced to the market and the recent economic contraction and slowing of growth may have reduced sales, compared to the recent past. However, increased use of central catering and use of refrigeration over freezing to store fresh food, as opposed to using frozen foods in food preparation, and greater use of blast chilling to raise hygiene levels and food quality for example, may mitigate some of the effects of contraction in the market. The main product trends are as follows: move toward packaged, plug-in products to avoid the need for trained installers; improved control systems to maximise system efficiency; and increased use of HCs and CO 2.to reduce environmental impact and preempt regulation. The data presented in Task 2 will play a part in formulating the Base Cases. Product price and lifetime data described in Task 2 are also key inputs for further analysis in Tasks 4 and Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

243 ANNEXES Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 45

244 This page is left intentionally blank 46 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

245 Annex 2-1 PRODCOM and EUROSTAT data The Eurostat database gives a first overview of the refrigeration sector in the EU. This database uses the PRODCOM 60 classification, and contains market data: per number of units and value ( ); for the EU-27 or per country; and per year since Even though the PRODCOM classification is not detailed enough to describe all the products identified in Task 1 61, the following product categories have been identified as relevant to this project: : Refrigerated show-cases and counters incorporating a refrigerating unit or evaporator for frozen food storage; : Refrigerated show-cases and counters incorporating a refrigerating unit or evaporator (excluding for frozen food storage); : Deep-freezing refrigerating furniture (excluding chest freezers of a capacity <= 800 litres, upright freezers of a capacity <= 900 litres); : Refrigerating furniture (excluding for deep-freezing showcases and counters incorporating a refrigerating unit or evaporator); : Other refrigerating or freezing equipment; : Combined refrigerators-freezers, with separate external doors; : Compression-type built-in refrigerators; : Chest freezers of a capacity <= 800 litres; : Upright freezers of a capacity <= 900 litres. The PRODCOM statistics have the advantage of being the official data source in the EU (hence they are used and referenced in other EU policy documents regarding trade and economic policy, providing consistency). Table 2-26 summarises the relevant data and gives an overview of the production, imports, exports 62 and apparent consumption 63 for the nine identified PRODCOM categories in units and million Euros for the EU-27 for the latest 3 years for which data are available. 60 Prodcom Classification: List of PRODucts of the European COMmunity 61 See BIO Intelligence Service. Working document on Task 1 published on 04/05/ available at 62 Data for Imports and exports provided in Table 2-26 include both intra-eu and extra-eu trade 63 Apparent consumption is defined as production + imports - exports Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 47

246 Table 2-26 Overview of the Eurostat EU-27 economic data for relevant product categories Prod. Imp. Exp Calculated apparent consump. Prod. Imp. Exp. Calculated apparent consump. Prod. Imp. Exp. Calculated apparent consump Total M. unit x10⁶ M. unit x10⁶ 1, , , ,142.7 M. unit x10⁶ M. unit x10⁶ , M. unit 4.0 N/A N/A N/A 4.8 N/A N/A N/A 3.0 N/A N/A N/A x10⁶ 2, , , , , ,966.9 M. unit 7.5 N/A N/A N/A x10⁶ 1, , , , , ,486.6 M. unit x10⁶ M. unit 3.3 N/A N/A N/A x10⁶ M. unit 2.4 N/A N/A N/A x10⁶ M. unit x10⁶ 9, , , , , , , , , , , , EU Production Figure 2-7 provides Member State (MS) level PRODCOM data for the EU-27 production for the nine PRODCOM categories mentioned above, for the most recent year for which data is available (2007). The aggregated estimates for the whole EU-15, EU-25 and EU-27 are also from the PRODCOM database. The production volume in EU-27 for the combined nine PRODCOM categories in 2007 is 22.7 million units corresponding to a total production value of 11,000 million. Figure 2-7 gives the distribution per MS. The PRODCOM data is not complete and some countries appear to have no production activity although this is probably not the case. The PRODCOM statistics show that leading MS in terms of production of commercial refrigeration products are: Italy, Germany, France, Poland, Spain, UK, Finland and the Netherlands. 48 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

247 Figure 2-7: EU-27 production of commercial refrigeration equipment in EU Trade EU imports and exports Annex 2-3 and Annex 2-4 present the PRODCOM data on intra- and extra- EU-27 imports and exports for the nine identified categories of PRODCOM per MS and for the EU-27 as a whole. Figure 2-8 and Figure 2-9 present the imports and exports distribution per MS in million Euros for the year Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 49

248 Figure 2-8: EU-27 commercial refrigeration equipment imports in 2007 Figure 2-9: EU-27 commercial refrigeration equipment exports in 2007 In the Eurostat database, the breakdown of the imports and exports into intra- and extra-eu-25 data is given according to the Harmonised System (HS) classification or according to the Combined Nomenclature (CN). Table 2-27 gives the equivalence between the PRODCOM, the HS and CN classifications. 50 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

249 Table 2-27: Equivalence between the PRODCOM, HS, and CN classifications PRODCOM Designation CN8 HS Refrigerated showcases and counters incorporating a refrigerating unit or evaporator for frozen food storage Refrigerated showcases and counters incorporating a refrigerating unit or evaporator (excluding for frozen food storage) Deep-freezing refrigerating furniture (excluding chest freezers of a capacity 800 litres. Upright freezers of a capacity 900 litres) Refrigerating furniture (excluding for deep freezing showcases and counters incorporating a refrigerating unit or evaporator) Other refrigerating or freezing equipment Combined refrigerators-freezers, with separate external doors Compression-type built-in refrigerators Chest freezers of a capacity <= 800 litres Upright freezers of a capacity <= 900 litres Annex 2-6 and Annex 2-7 present the breakdown of the extra EU-27 imports and exports by country of destination and of provenance according to the Eurostat HS6 data. The total extra-eu-27 imports and extra-eu-27 exports for 2008 for the six HS6 categories amounted respectively to 1,988 million (57% of the total intra- and extra-eu-27 imports) and 1,978 million (50 % of the total intra- and extra-eu-27 exports). The main countries of origin of imported commercial refrigeration equipment in EU-27 are China, Turkey, South Korea, and the US (see Figure 2-10). The main countries of destination for exported EU-27 commercial refrigeration equipment are Russia, Switzerland, Norway, and the US (see Figure 2-11). Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 51

250 Figure 2-10: Extra-EU imports per major country of provenance in 2008 Figure 2-11: Extra-EU exports per major country of destination in Apparent EU consumption Annex 2-5 shows the apparent consumption (defined as production + imports exports ) of commercial refrigerators and freezers as calculated from the official 52 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

251 Eurostat data. The total EU-27 apparent consumption for the year 2007 is estimated at 10,544 million and 26.8 million units METHODOLOGICAL ISSUES RELATED TO THE USE OF PRODCOM DATA As described, PRODCOM data are based on products whose definitions are standardised across the European community and thus allow comparability between MS data. The PRODCOM statistics also have the advantage of being the official EU source, used and referenced in other EU policy documents regarding trade and economic policy, hence guaranteeing EU consistency. However, the quality of these data can be challenged as the PRODCOM classification of ENTR Lot 1 products is not detailed enough to cover all the products identified in Task 1. Moreover, the PRODCOM categories do not explicitly state the product categories covered by each PRODCOM code. PRODCOM classifies commercial refrigerators and freezers in the category NACE Manufacture of non-domestic cooling and ventilation equipment. Commercial refrigerators and freezers explicitly appear in this classification. However, few criteria are used to identify the different types of products. In addition, as some of the commercial refrigerating and freezing equipment are similar to household equipment (e.g. service cabinets, hotel minibars), a degree of overlap between commercial and domestic refrigerating and freezing equipment may occur. Hence, these datasets will not be used for the purpose of this study and instead stock data will be calculated using sales data, as presented in the next section. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 53

252 Annex 2-2 Eurostat EU-27 production of lot 1 relevant products (2007) x10³ x10³ x10³ x10³ Production units x10⁶ units x10⁶ units x10⁶ units x10⁶ France Netherlands Germany Italy United Kingdom Ireland Denmark Greece Portugal Spain Belgium Luxemburg Iceland Norway Sweden Finland Austria Malta Estonia Latvia Lithuania Poland Czech Republic Slovakia Hungary Romania Bulgaria Slovenia Croatia Cyprus EU-15 TOTALS EU-25 TOTALS , ,059.5 EU-27 TOTALS , , Countries presented by date of entry into theeu 54 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

253 x10³ x10³ x10³ x10³ x10³ Production units x10⁶ units x10⁶ units x10⁶ units x10⁶ units x10⁶ France Netherlands Germany Italy , United Kingdom Ireland Denmark Greece Portugal Spain 1, Belgium Luxemburg Iceland Norway Sweden Finland Austria Malta Estonia Latvia Lithuania Poland , Czech Republic Slovakia Hungary Romania Bulgaria Slovenia Croatia Cyprus EU-15 TOTALS E-25 TOTALS 3, , , , , , , E-27 TOTALS 3, , , , , , , Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 55

254 Annex 2-3 Eurostat EU-27 Imports of lot 1 relevant products (2007) Imports x10³ x10³ x10³ x10³ units x10⁶ units x10⁶ units x10⁶ units x10⁶ France Netherlands Germany Italy United Kingdom 2, Ireland Denmark Greece Portugal Spain Belgium Luxemburg Iceland Norway Sweden Finland Austria Malta Estonia Latvia Lithuania Poland Czech Republic Slovakia Hungary Romania Bulgaria Slovenia Croatia Cyprus EU-15 TOTALS EU-25 TOTALS 2, EU-27 TOTALS 2, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

255 Imports x10³ x10³ x10³ x10³ x10³ units x10⁶ units x10⁶ units x10⁶ units x10⁶ units x10⁶ France , Netherlands Germany , Italy United Kingdom , , Ireland Denmark Greece Portugal Spain Belgium Luxemburg Iceland Norway Sweden Finland Austria Malta Estonia Latvia Lithuania Poland Czech Republic Slovakia Hungary Romania Bulgaria Slovenia Croatia Cyprus EU-15 TOTALS EU-25 TOTALS , , EU-27 TOTALS , , Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 57

256 Annex 2-4 Eurostat EU-27 Exports of lot 1 relevant products (2007) Exports x10³ x10³ x10³ x10³ units x10⁶ units x10⁶ units x10⁶ units x10⁶ France Netherlands Germany Italy United Kingdom Ireland Denmark Greece Portugal Spain Belgium Luxemburg Iceland Norway Sweden Finland Austria Malta Estonia Latvia Lithuania Poland Czech Republic Slovakia Hungary Romania Bulgaria Slovenia Croatia Cyprus EU-15 TOTALS EU-25 TOTALS 1, EU-27 TOTALS 1, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

257 Exports x10³ x10³ x10³ x10³ x10³ units x10⁶ units x10⁶ units x10⁶ units x10⁶ units x10⁶ France Netherlands Germany Italy , United Kingdom Ireland Denmark Greece Portugal Spain Belgium Luxemburg Iceland Norway Sweden Finland Austria Malta Estonia Latvia Lithuania Poland Czech Republic Slovakia Hungary , Romania Bulgaria Slovenia Croatia Cyprus EU-15 TOTALS EU-25 TOTALS , EU-27 TOTALS , Annex 2-5 Eurostat EU-27 apparent consumption for year Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 59

258 Apparent consumption x10³ units x10⁶ x10³ units x10⁶ x10³ units x10⁶ x10³ units x10⁶ France Netherlands Germany Italy United Kingdom 2, Ireland Denmark Greece Portugal Spain Belgium Luxemburg Iceland Norway Sweden Finland Austria Malta Estonia Latvia Lithuania Poland Czech Republic Slovakia Hungary Romania Bulgaria Slovenia Croatia Cyprus EU-15 TOTALS EU-25 TOTALS 1, , EU-27 TOTALS 1, , Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

259 Apparent consumption x10³ units x10⁶ x10³ units x10⁶ x10³ units x10⁶ x10³ units x10⁶ x10³ units x10⁶ France , Netherlands Germany Italy , United Kingdom , , Ireland Denmark Greece Portugal Spain 1, Belgium Luxemburg Iceland Norway Sweden Finland Austria Malta Estonia Latvia Lithuania Poland , Czech Republic Slovakia Hungary , Romania Bulgaria Slovenia Croatia Cyprus EU-15 TOTALS EU-25 TOTALS 3, , , , , , , EU-27 TOTALS 3, , , , , , , Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 61

260 Annex 2-6 EU Imports 2008 per major countries of provenance HS6 Code Total 2008 Extra-Imports x10⁶ x10⁶ x10⁶ x10⁶ x10⁶ x10⁶ x10⁶ China Turkey South Korea United States Japan Thailand Mexico Others (Total < 30M.) EU-27 TOTAL , Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

261 Annex 2-7 Extra-EU Exports 2008 by major country of destination HS6 Code Total 2008 Extra-Exports x10⁶ x10⁶ x10⁶ x10⁶ x10⁶ x10⁶ x10⁶ Total Russia Switzerland Norway United States Turkey United Arab Emirates Serbia Morocco Saudi Arabia China Australia Israel Angola South Africa India South Korea Japan Egypt Qatar Belarus (Belorussi) Algeria Bosnia and Herzegovina Mexico Kazakhstan Singapore Iran Hong Kong Canada Libya Kuwait Tunisia Chile Brazil Nigeria Thailand Argentina Moldova Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 63

262 HS6 Code Total 2008 Extra-Exports x10⁶ x10⁶ x10⁶ x10⁶ x10⁶ x10⁶ x10⁶ Total Cuba Oman Iraq Macedonia VietNam Montenegro Albania Bahrain Jordan New Zealand Lebanon Indonesia Pakistan Kenya Venezuela Georgia Ghana Senegal Taiwan Dominican Republic Peru Ethiopia Azerbaijan Philippines Syria Malaysia Colombia Others (Total < 3M.) EU-27 Total , Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

263 Prices of water dispensers Annex 2-8 Additional product data An estimate of the price of water dispensers based on catalogue data shows that the selling price of such products is between 100 and Prices of dessert and beverage machines An estimate of the price of dessert and beverage machines based on catalogue data shows that the selling price of such products is very large, ranging from 1,000 to 20, Prices of ice makers The preliminary price range for an ice-maker (producing ice cubes) is estimated to be between 550 and 5,500 depending on the capacity. Table 2-28 details the price ranges according to the type of ice-maker. A previous US study 65 estimates the price of an ice-maker to be around US$1,000 (approx. 735) for a 500lb/24h capacity (approx. 227kg/24h), which is lower than the preliminary data collected at this stage. Table 2-28: Average prices for ice-makers (2009) Capacity (kg/24h) Description Average selling price ( ) Ice-cuber 550 1, Ice-cuber 1,000 2,200 >30 Ice-cuber 2,200 5, Dessert and beverage machines Table 2-29: Sales and stock of dessert and beverage machines in 2008 by technical characteristic Technology Sales Stock (units) (%) (units) (%) TOTAL 150,000 1,500, Arthur D. Little, Inc. Energy Savings Potential for Commercial Refrigeration Equipment, Final Report Prepared for US Department of Energy Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 65

264 Water dispensers Technology Table 2-30: Sales and stock of water dispensers in 2008 by technical characteristic Sales Stock (units) (%) (units) (%) Bottled water 222, Mains water 55, TOTAL 277,778 2,500, Ice-makers Table 2-31: Sales and stock of ice-makers in 2008 by technical characteristic Technology Sales Stock (units) (%) (units) (%) TOTAL 120, , Market data for non-priority products Table 2-32 Estimated share of replacement sales in 2008 (EU-27) Product category Replacement sales (units) 2008 Share of replacement sales over total sales (%) Dessert and beverage machines 4, Water dispensers 254, Ice makers 111, Table 2-33 Calculated CAGR for the period Product category CAGR Dessert and beverage machines 0.9% Water dispensers 1.0% Ice makers 0.9% 66 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

265 Product type Source Dessert and beverage machines Table 2-34 Estimates of product lifetime Defra MTP 66 ADL ME Study estimates 1 (years) Study estimates 2 (stock/sales in 2008) Figure to be used in ENTR Lot 1 analysis * 10 - Water dispensers Ice makers 8 7 to * Assumed to be similar to water dispenser - : No data available/found 66 Defra statistics available at 67 Arthur D. Little, Inc. Energy Savings Potential for Commercial Refrigeration Equipment, Final Report Prepared for US Department of Energy Mark Ellis and Associates. Self-contained Commercial Refrigeration. March 2000 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 67

266 Configuration Packaged condensing unit with single compressor Market % 95% Evaporating temp. ( C) LT (-35 C) MT (-10 C) Market % commercial refrigeration 20% 80% Annex 2-9: RCU market distribution Cooling capacity (kw) kw average: 5-7 kw kw average: 20 kw >50 kw average: 50kW kw average: 5-7 kw Market % 95% 4% 1% 80% Compressor type Market % Reciprocating 95.0% Scroll 5.0% Screw 0.0% Rotary 0.0% Reciprocating 95.0% Scroll 5.0% Screw 0.0% Rotary 0.0% Reciprocating 95.0% Scroll 5.0% Screw 0.0% Rotary 0.0% Compressor motor drive Market % On/off 93% 2 speeds 5% VSD 2% On/off 98% 2 speeds 0% VSD 2% On/off 98% 2 speeds 0% VSD 2% On/off 90% 2 speeds 0% VSD 10% On/off 93% 2 speeds 5% VSD 2% On/off 98% 2 speeds 0% VSD 2% On/off 98% 2 speeds 0% VSD 2% On/off 90% 2 speeds 0% VSD 10% On/off 93% 2 speeds 5% VSD 2% On/off 98% 2 speeds 0% VSD 2% On/off 98% 2 speeds 0% VSD 2% On/off 90% 2 speeds 0% Condenser cooling Market % Total market % Air 100% 15.9% Water 0% 0.0% Air 100% 0.9% Water 0% 0.0% Air 100% 0.3% Water 0% 0.0% Air 100% 0.9% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.7% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 95% 0.2% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% VSD 10% Air 95% 0.0% Water 5% 0.0% On/off 93% Air 100% 50.9% Water 0% 0.0% Reciprocating 90.0% 2 speeds 5% Air 100% 2.7% Water 0% 0.0% VSD 2% Air 100% 1.1% Water 0% 0.0% Scroll 10.0% On/off 98% Air 100% 6.0% 68 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

267 Configuration Packaged condensing unit with twin compressors or more Market % 5% Evaporating temp. ( C) LT (-35 C) MT (-10 C) Market % commercial refrigeration 20% 80% Cooling capacity (kw) kw average: 20 kw >50 kw average: 50kW kw kw average: 20 kw >50 kw average: 50kW kw kw average: 20 kw >50 kw average: Market % 15% 5% Compressor type Market % Screw 0.0% Rotary 0.0% Reciprocating 90.0% Scroll 10.0% Screw 0.0% Rotary 0.0% Reciprocating 90.0% Scroll 9.0% Screw 0.5% Rotary 0.5% Compressor motor drive Market % 2 speeds 0% VSD 2% On/off 98% 2 speeds 0% VSD 2% On/off 90% 2 speeds 0% VSD 10% On/off 93% 2 speeds 5% VSD 2% On/off 98% 2 speeds 0% VSD 2% On/off 98% 2 speeds 0% VSD 2% On/off 90% 2 speeds 0% VSD 10% On/off 93% 2 speeds 5% VSD 2% On/off 98% 2 speeds 0% VSD 2% On/off 98% 2 speeds 0% VSD 2% On/off 90% 2 speeds 0% VSD 10% Total Condenser Market % market cooling % Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.1% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 9.5% Water 0% 0.0% Air 100% 0.5% Water 0% 0.0% Air 100% 0.2% Water 0% 0.0% Air 100% 1.1% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 95% 3.0% Water 5% 0.2% Air 95% 0.2% Water 5% 0.0% Air 95% 0.1% Water 5% 0.0% Air 95% 0.3% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% 0% 0% - 0% - 0% 0.0% 75% 25% scroll 100% - 100% screw 0% - 100% scroll 95% - 100% screw 5% - 100% Air 100% 0.8% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 95% 0.2% Water 5% 0.0% Air 95% 0.0% Water 5% 0.0% 0% 0% - 0% - 0% 0.0% 75% scroll 100% - 100% screw 0% - 100% 25% scroll 95% - 100% Air 100% 3.0% Water 0% 0.0% Air 100% 0.0% Water 0% 0.0% Air 95% 0.9% Water 5% 0.0% Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2 69

268 Configuration Market % Evaporating temp. ( C) Market % commercial refrigeration Cooling capacity (kw) 50kW Market % Compressor type Market % Compressor motor drive Market % screw 5% - 100% Condenser cooling Market % Total market % Air 95% 0.1% Water 5% 0.0% 70 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 2

269 European Commission DG ENTR Preparatory Study for Eco-design Requirements of EuPs [Contract N S ] Lot 1 Refrigerating and freezing equipment: Service cabinets, blast cabinets, walk-in cold rooms, industrial process chillers, water dispensers, ice-makers, dessert and beverage machines, minibars, wine storage appliances and packaged condensing units Task 3: User behaviour Final report Contact BIO Intelligence Service S.A.S. Shailendra Mudgal Jonathan Bain +33 (0) shailendra.mudgal@biois.com jonathan.bain@biois.com

270 Project Team BIO Intelligence Service Mr. Shailendra Mudgal Mr. Benoît Tinetti Mr. Jonathan Bain Mr. Raul Cervantes Mr. Alvaro de Prado Trigo Disclaimer: The project team does not accept any liability for any direct or indirect damage resulting from the use of this report or its content. This report contains the results of research by the authors and is not to be perceived as the opinion of the European Commission. The European Commission is not responsible for any use that may be made of the information contained therein.

271 Contents 3. Task 3: User behaviour Introduction Users of the products Sources of impacts Heat loads System functionality Refrigerant leakage Product durability Location and installation of product Appliance location Assembly and installation Product use Usage pattern Loading efficiency Overloading Foodstuff temperature Loading duration/frequencies Abnormal use of blast cabinets Product design and system controls Location of evaporator and condensing unit Temperature settings Lighting control Anti-sweat heaters and heating coils control Maintenance and repair practices Evaporator cleaning Condenser cleaning Maintaining door/compartment seals Compressor check Cleaning and sanitising the equipment Refrigerant leaks prevention and correction Additional maintenance practices Product life Economic product life Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3 3

272 End-of-life behaviour Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units Information available for users Service cabinets Blast cabinets Walk-in cold rooms Industrial process chillers Remote condensing units Benefits of eco-design and energy efficiency Existing initiatives Possible barriers to eco-design Lack of standard test procedures Focus on capital cost Lack of financial initiatives Significance of energy costs relative to overall operating costs Preference for stabilised technologies Design limitations Limited information Lack of trained technicians Conclusions ANNEXES Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3

273 3. Task 3: User behaviour 3.1. INTRODUCTION The location of refrigeration equipment, and the way in which it is installed, used and maintained, can have a significant impact on its energy consumption and environmental impacts. Product design and product information to some extent influences user behaviour, as could information campaigns and mandatory/voluntary standards. The aim of this task is to explore the user behaviour aspects and their influence on the energy and environmental performance of the ENTR Lot 1 products. Due to the nature of the products, refrigeration contractors might for certain product groups be considered as users, as they can be involved in the design, location, assembly or maintenance of the products (often through formal tendering and servicing contracts). The main underlying issues to consider are: heat loads putting higher demand on the refrigeration system or affecting system efficiency through variable loads; incorrect use of the product unnecessary increase of consumption through misuse or incorrect setting of controls; refrigerant leakage leading to release of refrigerant gases into the atmosphere and reducing refrigeration system efficiency; product durability impacts on the lifetime of the product and potential early replacement. The objective of this section is to describe user behaviour, covering the best practices in sustainable product use. Firstly, the user types for ENTR Lot 1 products are identified, then the major sources of potential impact are discussed. User behaviour during the installation and use phase is discussed, then product and system design, followed by maintenance and repair practice, and finally end-of-life user issues are identified. A number of governmental agencies and organisations 1 provide recommendations for smarter use of refrigeration equipment. Such strategies to reduce energy use aim to reduce the amount of cooling needed. This can be achieved through better equipment settings and reduction of heat losses and gains. An analysis of the influence of providing user information on real life efficiency of commercial refrigeration equipment is therefore provided USERS OF THE PRODUCTS The refrigeration equipment identified in Task 1 is used by a wide range of users, and both consumers and contractors have an impact on product performance, for example: 1 Such as the Government of South Australia Department of Transport, Energy and Infrastructure, Energy Smart Initiative (Australia), Natural Resources Canada Office of Energy Efficiency oee.rncan.gc.ca/industrial/equipment/commercial-refrigeration/operation.cfm?attr=4 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3 5

274 poor location of the product or faulty installation may lead to increased heat infiltration (and increased heat load on the refrigeration system during use); during use, consumer maintenance might involve cleaning of the condenser heat exchanger during use, while installation and service contractors would carry out repair and refrigerant leakage testing. The following tables provide a product-level description of users and the behaviours that may impact product performance. Table 3-1: Consumer users of ENTR Lot 1 equipment Equipment Consumer users 2 Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units Professional kitchens of all varieties, public and private catering facilities, hotels, light industrial food processing, and supermarkets Restaurants, public and private catering facilities, hotels, light industrial food processing Professional kitchens of all varieties, public and private catering facilities, light industrial food industry, retail establishments of many kinds: butchers, pharmaceutical, florists 3 Food processing, cold storage, and larger manufacturing processes 4 such as plastics moulding To connect to remote equipment in restaurants, catering facilities, hotels, supermarkets, butchers Consumer use impacts might come through use (e.g. use pattern, pre-cooling, loading, temperature selection) or maintenance (e.g. condenser cleaning). Contractor impact could come at installation (e.g. avoiding air infiltration and refrigerant leaks, choosing a good location to avoid heat sources) or maintenance (e.g. checking for refrigerant leaks). For plug-in products, input from contractors is likely to be low (no expertise is needed for installation, components are integral and refrigerant leakage is relatively low), but high for remote products (installing pipes to circulate refrigerant, repairs and checking for leaks) SOURCES OF IMPACTS There are four major sources of impact that are affected by user behaviour, leading to greater energy consumption or reduced environmental performance. 2 Deneen, Michael A.,Gross, Andrew C. The global commercial refrigeration equipment market. (Focus on Industries and Markets) Health sector (the requirements are particularly special in medical premises: see Annex 3-1), mortuaries, testing laboratories are sectors in wich cold rooms are used, but these are not included in the scope of ENTR Lot 1. 4 E.g. Plastics & Rubber; Lasers; Food & Beverage; Chemical & Pharmaceutical; Metal Working; Mechanical & Engineering; and Paper & Related Applications. 6 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3

275 HEAT LOADS Refrigerated equipment used to cool down and store foodstuffs requires constant refrigeration energy intake to offset: heat gains due to opening the appliance (convection) this is true for service cabinets, walk-in cold rooms, dessert and beverage machines, and ice-makers; heat gains through insulated surfaces of the equipment (conduction); heat gains through the radiation from surrounding surfaces; heat gains due to the components included inside the equipment (lighting, fans, defrost system, warm foodstuff, etc.). The efficiency of refrigeration systems can also be affected by varying loads, depending on its technical specifications (e.g. variable speed drives can be more efficient at part loads please see Task 4 for more detail). As a rule, the cooling capacity of refrigeration systems should be designed to match their heat load. However, load can be heavily affected by use behaviour, for examplethrough overloading a system, or a refrigeration system may be over-designed to account for extreme highs in loading (e.g. in summer months) and loaded to only a fraction of its capacity. Please see Task 4 for more discussion on system loading and technical solutions SYSTEM FUNCTIONALITY The performance of service cabinets, blast cabinets and walk-in cold rooms can be impacted by improper stock loading, affecting air flows from the evaporator. Additionally, inadvertent misuse of system controls can lead to increased energy consumption across all products, for example through incorrect setting of the thermostat REFRIGERANT LEAKAGE Refrigerants and their impacts are discussed in detail in Tasks 1 and 4. The main impacts due to use arise through poor installation and maintenance of refrigerant circuit piping, leading to leaks this is particularly problematic at joints in the piping, but user aspects (as opposed to technical aspects of refrigerant selection) can be addressed through good practice. In addition to the direct impact of high-gwp refrigerants escaping into the atmosphere, reduced refrigerant charges also affect system efficiency, leading to higher energy consumption PRODUCT DURABILITY The durability of refrigeration equipment can be affected, and lifetime reduced, by damage to the refrigeration system or physical damage to the product LOCATION AND INSTALLATION OF PRODUCT APPLIANCE LOCATION Refrigeration equipment is often used in kitchens (near cooking appliances) without any air-conditioning systems, or can be used outdoors in potentially high ambient temperatures during summer (or direct sunlight). In industry, process chillers may be Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3 7

276 placed in areas of high ambient temperatures or located near heat sources such as industrial equipment. Refrigeration equipment should be located in a cool and well-ventilated area to optimise its operation and reduce energy consumption. Remote condensation can also reduce energy consumption of refrigeration systems due to potentially lower ambient temperature at remote locations. Manufacturers recommend that plug-in equipment should be located in well-ventilated areas (with air-conditioning) to provide good ventilation (air flow) for the condenser coils and fans. Avoiding direct sunlight, dusty areas (see ), and locations near heated units results in higher energy efficiency of refrigeration products, as does providing good ventilation ASSEMBLY AND INSTALLATION Assembly and site installation can have a significant impact, particularly for remote product types and field-erected products such as walk-in cold rooms. If these products are installed in a sub-standard manner, the insulation housing may be poorly joined (leading to refrigerant leaks) or have reduced durability and a shorter lifetime. In the case of pumps, the performance of a water pumping system can be decreased by 28% to 56% due to poor installation 5. Good installation is also crucial to avoid refrigerant leaks, when constructing the piping for the refrigerant circuit. Stakeholders 6 have mentioned the importance of proper installation for chillers, due to which energy efficiency can vary from 50% to 85% (depending on the auxiliary equipment required by these machines), e.g.: Piping, which can reduce or increase pressure drops; pumps; heat exchangers (cooling towers or air coolers); water treatment plants, to avoid corrosion, biological contamination or biofilm formation. Other stakeholder feedback has suggested that effective fine-tuning of a process chiller to its refrigeration system, and proper selection of water temperature, can save as much as 30% of energy consumed by better management of pumps and chiller operation at partial load. However, these gains depend on the operation conditions. By setting the parameters of the system to match the actual load of the equipment, it will perform at its best efficiency. The different elements are not over- or sub-loaded, therefore no waste energy is produced. Effective fine-tuning of refrigeration systems and controls could provide savings for other product groups. 5 M. Merchat, Mesure des performances énérgétique des systémes de refroidissement, Source: EUROVENT 8 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3

277 3.5. PRODUCT USE USAGE PATTERN Little data is available in the literature on estimates of the typical usage patterns of products, however first estimates have been made and are described in Table 3-3. Commercial refrigeration appliances such as professional service cabinets are typically used 24 hours a day, without interruption, even during the weekends. However, more specific products have more complex usage patterns, which will need to be further investigated. Blast cabinets are used for batch chilling, and are activated only when they are required. The use patterns suggested by stakeholders are presented in Table 3-2. The use of these units will depend on the type of business in which they are installed. For example, a catering operation with a large customer base may use the equipment regularly for the high volume of food processed, while a restaurant may use the equipment only at mealtimes and hence less frequently. The final use pattern is an average of these (Table 3-3). Stakeholders commented that although the products are often able to both chill and freeze, the freezing function is rarely used. Process chillers used in the industry run only half of the day (see Table 3-3). However, process chillers used in food storage are meant to run 24 hours per day. It is estimated that process industrial chillers are more representative of the market, but no accurate data have been found regarding the proportion (comments from stakeholders are welcome). Table 3-2: Estimated blast cabinet use according to stakeholders Stakeholder Type of Cycles per cycle 1 day Days per year Hours per year 1 Chilling ,560 2 Chilling Freezing ,440 3 Chilling ,063 Freezing ,200 4 Chilling 2 - Freezing 1-5 Chilling Freezing ,040 Chilling Agreement during stakeholder meeting 2 Freezing Combined 1: ,210 1 Chilling cycle = 90min, freezing cycle = 240min 2 25 th /10/2010. Brussels. Re-consulted with stakeholders absent from the meeting Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3 9

278 Table 3-3: Usage pattern for ENTR Lot 1 equipment Source Equipment UK Defra Estimate used MTP 7 (h/year) (h/year) Service cabinets 8,760 8,760 Chilling models: 660 (two 90-minute chilling cycles per day, 220 days per year, an estimate based on stakeholder feedback)* Blast cabinets N.A. Freezing models: 880 (one 240-minute freezing cycle per day, 220 days per year)* Walk-in cold rooms Industrial process chillers Remote condensing units N.A. : Not available at this stage * Estimated average Chilling/freezing: 1,210 (one 90-minute chilling cycles plus one 240-minute freezing cycle per day, 220 days per year)* 4, ,760 4,380 4,380 N.A. The use of the condensing unit depends on the product it is connected to, hence could vary from 1,650 for a blast cabinet to 8,760 for a walk-in cold room). The industry standard for the duty cycle is 16h/day, according to information provided by stakeholders. This means 5,840h/year LOADING EFFICIENCY Commercial refrigeration appliances designed to store and cool foodstuff items, i.e. service cabinets, walk-in cold rooms, and blast cabinets, are affected by load efficiency. Good management of refrigeration needs can reduce the amount of cooling space needed. In the food distribution business, proper identification of requirements can enable less refrigeration. For example, one service cabinet with proper and full stocking is more efficient than two which are half-full Overloading Most end-users fill their appliances with too much foodstuff, despite the "load limit" indications on the cabinets/storage rooms (load limit shows the maximum filling of the cabinet). In the case of service cabinets, blast cabinets, and walk-in cold rooms, overloaded refrigerated spaces decrease product quality and increase energy use by 10% to 20% per unit 8, by disturbing the internal air flow. Bigger supermarkets and restaurants usually adhere to loading prescriptions more rigorously, due to stricter control from national health departments. Overloading is typically observed more frequently in small convenience stores/small users. 7 8 UK Defra statistics available at whatif.mtprog.com Sacramento Utility District Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3

279 Load limit indications on the cabinet/storage rooms (load limit shows the maximum filling of the cabinet/storage rooms) need to be clearly visible and understandable by the enduser. Additionally, users should be aware of the manufacturer's recommendations for shelf positions and sizes, to prevent increased refrigeration loads. In the case of process chillers, users should be fully aware of the cooling capacity of the appliance, so as to choose the appropriate size to fit their cooling needs Foodstuff temperature Foodstuff temperature, or water inlet temperature, is relevant to service cabinets, blast cabinets, walk-in cold rooms and process chillers. Please see Task 1 for a description of relevant national food hygiene regulation and HACCP. The temperature of foodstuffs should be kept low when placed in the refrigeration equipment, as refrigeration products are designed to store foodstuffs at a low temperature and not to pull down warm temperatures. Pulling down the temperature of foodstuffs from the ambient temperature to the refrigerated temperature increases the energy demand. Blast cabinets are specifically designed to cool down products (but can also maintain the foodstuff at a low temperature if required), and energy savings are achievable through leaving foodstuff to cool in ambient air before loading into the blast cabinet. Ambient pre-cooling is an option in those countries where the legislation allows this procedure. This step could be considered for blast and service cabinets in order to decrease the energy consumption of the equipment. However, this must agree with existing food safety legislation parameters. Temperature at the time of loading into refrigeration equipment can also be an issue with non-perishable items, such as drinks, which are loaded at ambient temperature and therefore a significant increase in energy consumption is required to pull down their temperature. Users should be informed that storing goods in hot areas (e.g. in direct sunlight) should be avoided before they are loaded in refrigeration equipment, and that storing goods in a cool area and then loading the products could save energy. Pre-cooled products should be transferred as quickly as possible from one refrigerated area to another, to prevent their temperature from rising Loading duration/frequencies The time taken to load the foodstuff, during which a refrigeration product s door(s) is (are) left open, allows heat infiltration from the ambient warm air, and this can influence the energy consumption of refrigeration equipment. Service cabinets and walk-in cold rooms are subject to heavy usage; doors are opened hundreds of times during a day 9 which increases the heat infiltration. Information to raise awareness on the energy losses due to excessive door openings should be provided Abnormal use of blast cabinets It has been mentioned by stakeholders that some blast equipment is used for steady-state cold storage, after the blast cycle (i.e. as a service cabinet). Although it can be used in this way, blast equipment is not meant to hold the foodstuffs for long periods of time. As blast cabinets are designed to rapidly cool hot food, the powerful refrigeration system is 9 Deneen, Michael A.,Gross, Andrew C. The global commercial refrigeration equipment market. (Focus on Industries and Markets) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3 11

280 unsuited to the low demands of maintaining food temperature. Therefore this type of use has high energy consumption. No further information about the frequency of this type of behaviour has been found. In addition, some chiller/freezer products do not include defrost systems, as they are thought to never be required to freeze product during typical use (this is according to manufacturers market research). When electric defrost systems are included, they are normally manually activated. Build-up of ice can increase energy consumption during use through reduction of heat transfer across the evaporator PRODUCT DESIGN AND SYSTEM CONTROLS Other use characteristics can also influence the energy consumption of refrigeration equipment LOCATION OF EVAPORATOR AND CONDENSING UNIT The location of the evaporator and condenser can affect ease of cleaning. For example, condenser heat exchangers can be more easily accessed and cleaned if located at the top of a service cabinet (please see and ). The location of the condenser is also important for system performance poor quality of air flowing around it can lead to buildup of dust or grease, which reduces its heat transfer capacity TEMPERATURE SETTINGS For refrigeration equipment designed for storage of foodstuffs, two levels of temperature exist: medium temperature (MT) (-2 C to +2 C), for preservation of fresh food, and low temperature (LT) (-18 C to -25 C) for preservation of frozen food. Differences between the recommended temperature (fixed by food and safety regulations) and the actual working temperatures can sometimes be observed. For refrigerated cabinets, it is estimated that every degree below the required temperature increases the appliance s energy consumption by 2% to 3% 10. These differences can occur when the cabinet thermostat is set to food safety temperature values and not to manufacturer s recommended values, due to the position of the control temperature probes inside the service cabinet. The displayed working temperature of the cabinet (thermometer) can be slightly different from the real temperature inside the refrigerated volume of the cabinet (higher or lower depending on the probe position). Unnecessarily low temperatures waste energy and do not provide any benefits. For maximum energy savings, temperatures should be set and kept at the maximum authorised temperature. As temperatures are often set lower than necessary a regular check of the temperatures could help to reduce energy consumption. In this situation, manufacturers should give the right information regarding the correlation between the displayed temperature (set by the thermostat) and the real cabinet working temperature. 10 Government of South Australia - Energy SA Advisory Service 12 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3

281 A possible measure to avoid this might be to require all products to provide straightforward and accurate display of internal temperature, and allow its control, to avoid confusion LIGHTING CONTROL Use of lower wattage light bulbs helps in reducing the amount of heat released and thus saving equivalent refrigeration energy. Switching off lights when unnecessary (e.g. during lunch hours) may result in overall reduction of energy consumption. Lights bulbs are not normally used in blast cabinets, but are used in service cabinets and walk-in cold rooms ANTI-SWEAT HEATERS AND HEATING COILS CONTROL Anti-sweat heaters and heating coils ensure that no condensation occurs and are often used in appliances with doors, such as service cabinets and in walk-in cold rooms (either remote or plug-in), to reduce condensation around the door seals. They commonly stay on at full load for 24 hours a day, and the heat generated by these components adds to the required cooling load. They are typically used 24 hours per day in low temperature cabinets (frozen) and 12 hours a day in chilled refrigeration equipment 11. The use of anti-sweat heaters can be controlled by switches responding to local dew point or humidity conditions. Appropriately placed sensors can measure the dew point and allow the heater to switch off when not required. For example, energy savings can be achieved by reducing the use of such heaters when the ambient air is colder and has a lower humidity. Heating coils could also be replaced by a hot gas line running from the compressor to the door frame (for plug-in products only) MAINTENANCE AND REPAIR PRACTICES The objective of this section is to describe user behaviour in relation to the use phase, covering real-life maintenance and repair practices. No information has been found to describe typical EU practices in terms of product repair. Regular basic maintenance on refrigeration equipment, which should be carried out approximately twice a year, includes the following practices 12 : cleaning the evaporator; cleaning the condenser; checking the compressor; maintaining the door/compartments seals; cleaning and sanitising equipment. 11 Arthur D. Little, Inc., Energy Savings Potential for Commercial Refrigeration Equipment Final Report, Building Equipment Division Office of Building Technologies U.S. Department of Energy, June Mitchell, N. Annual Systems Inspections Reduce Electric Energy Consumption. ASERCOM Symposium, Nuremburg Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3 13

282 These practices do not apply across all refrigeration equipment covered in ENTR Lot 1.Table 3-4 Table 3-4 identifies the correspondence between appliances and their maintenance practices. Energy efficiency issues Health issues Table 3-4: Different basic maintenance practices across ENTR Lot 1 products Maintenance practice Service cabinets Blast cabinets Walk-in cold rooms Industrial process chillers Remote condensin g units Evaporator cleaning x x x x Condenser cleaning (for appliances incorporating a x x x x x condenser only) Maintaining door/compartments x x x seals Compressor check (for plug-in appliances only) x x x x x Cleaning and sanitising equipment (once a x x x month) The different maintenance practices and their impacts on the product performance are described below EVAPORATOR CLEANING Cleaning the evaporator coils every month and keeping them unobstructed can improve energy efficiency. Blocking or partial blocking of the fin coils and oil logging (oil escaping from the compressor) will reduce the evaporator temperature, which reduces the cooling capacity. The desired cooling temperature might therefore not be reached. Specially formulated cleaning solutions are available to clean the specific sediment that can collect over time in evaporators. Cleaning the evaporator annually can prevent the sediment from building up, and increase energy efficiency. However, cleaning the evaporator requires the power to be shut off and the drain tube to be disconnected. The bottom pan of the evaporator coil can then be unscrewed and removed, and the components accessed for cleaning CONDENSER CLEANING The cleanliness of the surface of the air-cooled condenser is very important. If condenser coils get too dirty, the compressor discharge pressures can get high enough to make the compressor cycle off under the action of the high pressure cut-out switch in a short period of time. A regular check on this component can prevent reaching high discharge pressures, resulting in higher efficiency. In the case of an air-cooled condenser, even if the condenser is located in a ventilated area, if the air cannot directly contact the heat transfer surface because of dust and dirt (see Figure 3-1) the condensing temperature will rise. Keeping the condenser coils clean will help reduce the electricity consumption. For example, in the case of beverage 14 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3

283 merchandisers, manufacturers recommend that the condenser should be cleaned at least twice a year. A case study 13 in the UK showed that electricity savings of as much as 8% could be achieved for a top-mounted plug-in vertical freezer service cabinet, located in a canteen, just by cleaning the condenser. Figure 3-1: Top-mounted condenser on plug-in service cabinet before/after cleaning 13 In the case of water cooled condensers 14, the condenser should be checked in case of corrosion and scale formation. Tube scaling and fouling can be monitored by logging pressure drops across the condenser bundles. Cleaning the condenser fan blades also ensures increased energy efficiency MAINTAINING DOOR/COMPARTMENT SEALS Regular checks to verify that the door seals are providing sufficient insulation can also result in energy savings, by preventing heat leakages. In busy situations gaskets are prone to damage. They should be checked on a regular basis and replaced when needed COMPRESSOR CHECK Compressor maintenance includes the following practices: vibration analysis; checking all alignments to specifications; checking all seals; checking the oil system (oil and filter); checking all strainers, valves, etc CLEANING AND SANITISING THE EQUIPMENT In the case of ice-makers, the ice produced is consumed by customers; therefore the icemaker is considered a food contact surface area. Following manufacturer's instructions, the appliance should be cleaned and sanitised at least once a month. Cleaning will remove scale/lime build-up and other mineral deposits and sanitising will remove harmful 13 Mark J. Swain. Energy use in the catering sector, Case study Refrigeration at the Langford canteen. University of Bristol FEMP O&M Best Practices Guide 2.0., FEMP Continuous Commissioning Guidebook for Federal Energy Managers. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3 15

284 bacteria, algae and slime growth. This also applies for other appliances which have a direct food contact area (dessert and beverage machines, and water dispensers). Service cabinets, walk-in cold rooms and blast cabinets do not come directly in contact with foodstuffs, but also need to be regularly sanitised and cleaned. In service cabinets and blast cabinets, the condensate drain lines can be blocked by spillages and debris (resulting from defrost operations), causing leaks and generating a possible health risks. Indeed, the drains and condensate trays are a breeding ground for bacteria which can multiply at a very fast rate. Correct condensate tray and drain sanitisation and regular cleaning will initially remove the bacterial growth 15. Hygiene in walk-in cold rooms is important, particularly if dealing with fresh meat and produce, as fatty deposits from foodstuff can contaminate and restrict the airflow. Regular sanitisation with a food-safe sanitiser will break down and remove fatty deposits stuck on evaporator fins, and ensure that hygiene levels are maintained. Walk-in cold room walls, floors, ceilings and internal shelves also require cleaning and sanitising REFRIGERANT LEAKS PREVENTION AND CORRECTION Refrigerant leaks have been reduced slightly in the last years, due to the refrigerant charge reduction, according to information received from stakeholders, but the average annual leakage rate is around 10%. In remote systems, where professional installation and pipes connections are needed, this leakage is higher than in plug-in applications. These refrigerant leakages directly affect the efficiency of the product and the environmental impact, when the refrigerant s GWP or other environmental impacts are not negligible. Indirectly, the energy efficiency also affects the total environmental impact of the product throughout its life cycle. There are some voluntary agreements in the industry regarding refrigerant leakage prevention, i.e. the UK Institute of Refrigeration (IOR) published a revised Minimisation of refrigerant emissions code 16 in This covers all the commonly used refrigerants and gives recommendations regarding F-gas and ODS regulations ADDITIONAL MAINTENANCE PRACTICES Additional maintenance practices 17 that are recommended to be performed at least twice a year include: verifying the electrical connections (insulation, tightness of electrical connections, fuse check, electrical contacts, etc.); checking the defrost, or anti-sweat, system (control and heaters); checking any water pipes and waste water pipes for leaks; and oiling accessible moving parts such as door hinges. 15 Myddleton Maintenance Services Ltd 16 IOR, Minimisation of Refrigerant Emissions Code APEX Commercial Refrigeration & Air Conditioning Ltd. 16 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3

285 3.8. PRODUCT LIFE ECONOMIC PRODUCT LIFE The economic product life, in the case of refrigeration products, is assumed to be less than the technical life. Hence in real-life, a product may be replaced for cost, hygiene or aesthetic reasons, even if the technical components continue to function properly. Section in Task 2 provides preliminary average economic product life estimates which will be used in LCC calculation during Tasks 4 and END-OF-LIFE BEHAVIOUR Commercial refrigeration equipment is often replaced for either economic, aesthetic or hygiene reasons, even though it is still operational. There are three main routes for end-of-life: selling the product on the second-hand market; sending the product to the manufacturer for proper recycling and disposal; sending the product to a specialist plant for recycling and use of scrap metals. In EU refrigeration equipment recycling facilities, less than 1% of the appliances are commercial equipment. Most of the commercial refrigeration equipment is therefore refurbished and introduced into the second-hand market. The used equipment is generally sold in East and Central Europe or in African/Asian countries. 18 Other practices also exist. For example, when the equipment is not suitable for second hand use, some retailers sell the old equipment to scrap metal dealers. Valuable materials such as copper, aluminium and steel are then recovered Service cabinets Professional service cabinets fall under the WEEE Directive, and due to their small size they can be disposed of within the domestic refrigeration waste stream. However, compliance with this may vary greatly depending on in which Member State the manufacturers are located 19. It is estimated that over the life of the product, 100% of its refrigerants will be released to the atmosphere 20. Best practice for recycling would include 21 : Arrival of Product & Inspection. Removal of parts, shelving, castors and microprocessor Parts removed sent to re-processors. All re-processors are licensed by the Environment Agency as Treatment Facilities. Refrigeration system de-gassed and oil removed into separators Refrigerant gas placed in pressurised containers. High temperature incineration converts it to harmless salts. Compressor oil is reclaimed & sent to Energy from Waste (EfW) a process which recovers energy from waste materials in a controlled and 18 Stakeholder feedback 19 Source: Gram, ECOS 20 Source : ECOS 21 As provided by Foster Refrigerator Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3 17

286 regulated environment. This is supplied to the National Grid to support Green electricity. Removal of compressor Empty compressors sent to re-processing metal plants. Remainder of product crushed. Crushed products placed in sealed chamber filled with Nitrogen Gas The product is then shredded into small pieces. A magnetic separator collects all the ferrous metal. An eddy current separator collects all the non ferrous metals. Polyurethane foam is treated with heat and mechanical pressure is applied to release more CFC/HCFC gas Gas is removed and rapidly cooled in liquid nitrogen. This turns the removed gas into a liquid. It is stored in pressurised containers and re-processed. Foam pellets are produced & recycled for plastic plate manufacture, oil spill absorbents or used in Energy from Waste (EfW). Plastic separated out and sent to re-processor Plastic is recycled into horticultural products Blast cabinets Blast cabinets should comply with the WEEE Directive. This equipment should be dismantled by specialist companies. Blast cabinet manufacturers recommend taking the following measures at the end-of-life: not disposing of the equipment directly into the environment; removing doors and locking systems, in order to avoid potential accidents; roughly dismantling the appliance by taking away wiring, and any removable parts; recycling oil and refrigerant; delivering the equipment to specialised collection and destruction centres. It has been mentioned by stakeholders that a large share of the machines manufactured in the EU is sold outside the EU Walk-in cold rooms Little information is available on the end-of-life practices for walk-in cold rooms. Stakeholders have stated that smaller products using packaged refrigeration systems are likely to be disposed of without treatment. Therefore, refrigerant charges are thought to be disposed of at the end-of-life. Larger systems with larger charges are thought to have a proportion of their charge recovered, due to its value and greater perceived consequences of its release 22. On average, assuming that there is annual leakage and refilling of the charge, it is estimated that over the life of the product more than 100% of its original refrigerant charge will be released to the atmosphere 23. It is thought that the panels and other enclosure components are disposed of, given that the insulation will degrade over life, and that the system and other electronic components 22 Source: ECOS, GR Scott 23 Source : ECOS 18 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3

287 are either refurbished for resale or recycled for scrap metals. Some insulation panels are constructed to allow disassembly and reassembly for re-use 24. In addition, well-preserved cold rooms can be sold second-hand, but remote condensing units need to be in very good, current condition to be re-sold after first use Process chillers According to stakeholders (Daikin, Trane, 2010), chillers are almost 100% recycled at the end-of-life, due to the large amount of valuable metal that they contain. Only the electronic parts are wasted, representing about 0.1% of the total weight of the appliance. Some comments have indicated that the price of a 4MW process chiller to be sold at the end-of-life can reach between 5,000 and 10,000. Due to the large amount of materials within these units, they are not likely to be dumped without proper treatment and refrigerant recovery. However, opinions regarding this point are not consistent; the proportion of refrigerant disposed of at the end-of-life ranges from 10 to 80% 25. An average of 50% is being considered for this value Remote condensing units It is assumed that remote condensing units are either refurbished for resale or recycled for scrap metals. The greater part of remote condensing units is usually recyclable (metals, plastics), and waste treatment facilities sell the mixture of copper and aluminium to motor manufacturers. During correct end-of-life management, the refrigerant is reclaimed and the rest of the product is shredded, separating the different materials for recycling by air-vacuuming and magnets. Approximately 70% of the content is ferrous metals, with the rest being nonferrous metals, plastics and others. However, estimations of real practices regarding the reclamation of refrigerants at the end-of-life show that between 50% and 95% of the refrigerant charge is released to the atmosphere, depending on the country INFORMATION AVAILABLE FOR USERS The objective of this section is to analyse whether providing users with information regarding the product s sustainable use and ecological profile would have a significant positive environmental impact. For example, information related to refrigeration appliances can have a significant impact on the equipment s energy efficiency as improving simple operational and maintenance practices can reduce energy consumption by 15 % or more 27. Strategies to reduce energy use and refrigerant leakages are described below. Stakeholders have discussed how the initial capital cost of products is the main concern for end users. There is also a significant difference between the types of end user. Large corporate consumers of refrigeration equipment may have well organised maintenance 24 Source: Smeva 25 Source: ECOS 26 Clodic et al. Global inventories of the worldwide fleets of refrigerating and air conditioning equipment in order to determine refrigerant emissions. The 1990 to 2006 updating. 27 Australia Energy Smart Initiative - Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3 19

288 departments who are able to perform necessary tasks to ensure high product performance. However, many users are small and may not have the technical understanding of the products to be aware of the maintenance needs and impacts of poor maintenance. This also depends on the type of the product: products requiring installation (such as remote condensing units, compressor packs, industrial chillers, walk-in cold rooms) are bought by the contractor/installer and the end user does not decide on the energy efficiency of the machine, whereas small plug-in products can be directly purchased by the end user and a higher efficiency could be a driver in the purchase decision. Energy labelling would therefore be beneficial to highlight the significant variability in products energy consumption, particularly plug-in products that are sold directly to consumers (such as service and blast cabinets, and for small walk-in cold rooms) and the resulting life cycle cost. For remote and more complex products, such as process chillers, larger (remote) walk-in cold rooms and remote condensing units, an energy label would be more challenging to implement and may be less effective. These products, often used for applications requiring more specific performance (i.e. process chillers), would either be sold to more knowledgeable users or a refrigeration contractor/installer who are aware of performance issues. Therefore, a high efficiency guarantee label (without necessarily covering energy consumption but ensuring use of high performance components) may be more appropriate for these products, to demonstrate to the end user that the product has been designed to be energy efficient. User manuals should include information on best user and maintenance practices for all products, to maximise the potentially high energy savings that basic maintenance can allow. These alternative policy options will be further discussed in Task SERVICE CABINETS Service cabinets are usually bought by end users and thus an energy labelling scheme or other energy information to the consumers could influence the purchase decision towards more efficient products. Recommendations for energy efficient use to the end users in technical specifications brochures can also promote a more efficient use pattern, and in addition recommendations for best maintenance practices could improve product performance, resulting in lower energy consumption during the use phase of the product BLAST CABINETS Blast cabinets are also usually bought by end users. An energy labelling scheme may be relevant, influencing purchasing decisions by differentiating products by energy efficiency. Again, recommendations for energy efficient use and best maintenance could promote more efficient use patterns, resulting in lower energy consumption during the use phase of the product WALK-IN COLD ROOMS A major concern for walk-in cold rooms is the proper installation of the room however, this is usually carried out by a contractor. Best practice installation guidance for the product, or at industry level, may encourage improve installation quality, thereby reducing 20 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3

289 energy consumption however, this would not be likely to be directed at the final enduser. Open doorways are probably the biggest cause of concern regarding energy wastage. Training staff to close doors is paramount 28. An energy labelling scheme for walk-in cold rooms is considered to be less practical than for other products, due to the variability of the products. As for service and blast cabinets, recommendations in user manuals for best use and maintenance practice could result in lower energy consumption during the use phase of the product INDUSTRIAL PROCESS CHILLERS Due to their complexity and variation in performance depending on location (ambient temperature) and application, it is considered impractical to establish an energy labelling scheme for chillers. It may however be of benefit to provide end users with a standardised measure of performance (such as seasonal COP) to enable differentiation. In addition, recommendations to end users on best practice for use and maintenance of the chiller in order achieve best performance and efficiency could help to reduce energy consumption REMOTE CONDENSING UNITS Remote condensing units are usually purchased by the contractor or installer, and the decision is usually driven by the initial cost more than by the energy performance of the product. When this kind of products is usually used in big stores, the savings associated to the performance of the product are negligible compared with the total energy consumption of the store. Remote condensing units can be installed on different applications (walk-in cold rooms, display cabinets, etc) and thus the use pattern can be different depending on the system requirements. However, recommendations to end users on the correct adjust and maintenance of the condensing unit in order to get a correct performance and efficiency can help to achieve lower energy consumptions BENEFITS OF ECO-DESIGN AND ENERGY EFFICIENCY EXISTING INITIATIVES As seen in Task 1, in the EU there are very few energy efficiency programmes to promote efficient refrigeration appliances (apart from the UK Enhanced Capital Allowance scheme and Eurovent programme), and there are no incentives at the EU level to communicate the ecological profiles of commercial or industrial refrigeration products and the benefits of eco-design. In the US, Energy Star 29 labels commercial refrigerators and freezers (i.e. service cabinets) that are more energy efficient (designed with components such as ECM evaporator and condenser fan motors, hot gas anti-sweat heaters, or high-efficiency compressors), and 28 Source: Fermod 29 US Energy Star Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3 21

290 which will significantly reduce energy consumption and utility bills. Compared to standard models, Energy Star labelled commercial refrigerators and freezers can lead to energy savings of as much as 35% with a 1.3 year payback. Commercial ice machines that have earned the Energy Star are on average 15% more energy-efficient and 10% more waterefficient than standard models. However, preliminary data on the improvement potential 30 through better design of the refrigeration equipment included in ENTR Lot 1 show that there could be room for product differentiation, based on product performance (in terms of electricity consumption). The examples suggest that labelling efficient (eco-designed) products can communicate such advantages to consumers. However, in the EU, due to the absence of either voluntary or mandatory certification programmes to communicate on the performance of products, there is little incentive for manufacturers to improve their products. Section further elaborates on the possible barriers for eco-design and take-up of more efficient products regarding environmental impacts POSSIBLE BARRIERS TO ECO-DESIGN Lack of standard test procedures One major barrier to the implementation of eco-design measures is the current lack of standard procedures to measure the energy use for certain product categories (see Task 1). Without harmonised standards, it is difficult to accurately compare and monitor the energy performance of different refrigerating equipment produced by different manufacturers. Furthermore, without the confidence in the data that harmonised standards provide, it is difficult to make energy efficiency incentives, schemes or policies a reality Focus on capital cost Purchase decisions for refrigeration equipment are generally not made on life cycle cost (LCC) or payback considerations. Equipment buyers (small end-users, medium end-users or large supermarkets) normally select the equipment that meets specifications at the lowest capital (upfront) cost. For medium-sized end-users and large supermarkets, the individuals in charge of selecting the equipment do not focus on energy efficiency as a choice criterion because they are generally not in charge of operating it, nor paying the final electricity bill. Additionally, instead of energy performance, end-users tend to focus on design, size, and additional functions at the time of purchase. The main reason for this is that end users are often unaware of how significant the difference in life cycle cost can be Lack of financial initiatives The UK ECA is the only programme identified which provides financial incentives for investment in energy-efficient commercial refrigeration equipment in EU. 30 See BIO Intelligence Service. ENTR Lot 1 - Working Document on Task 1, published on 04/05/ T. Kubo and S.Nadel. Commercial Packaged Refrigeration: An Untapped Lode for Energy Efficiency. Report for the American Council for an Energy Efficient Economy Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3

291 In the UK, end users can benefit from tax concessions when they choose to buy energyefficient products. The full list of complying products is available online 32. Among the products included in ENTR Lot 1, the ECA covers packaged chillers and professional service cabinets. Compared with the energy thresholds presented by ECA and other MEPS, e.g. in the US or Canada, the ECA is less demanding Significance of energy costs relative to overall operating costs Energy costs may be small compared to other operating costs (e.g. wages and other expenditures). This could increase the tendency to disregard energy efficiency when evaluating ( sales-boosting ) design changes which can decrease initial capital cost of the equipment Preference for stabilised technologies 33 Technologies diverging from current practice take time to grow into a significant portion of the market. Indeed, the switch to natural refrigerants for remote equipment requires that technicians know how to install and operate refrigeration systems with these new refrigerants. Therefore, training of technicians is a preliminary requirement (and expense) before the roll-out of these new refrigerants Design limitations For service cabinets, blast cabinets, and walk-in cold rooms, an increase of the insulation thickness is undesirable. This would result in a decrease in storage volume, which would reduce sales capacity of a given unit. Hence this route to increasing energy efficiency of products is often undesirable Limited information End users are often not aware of the differences in energy efficiency between competing products (potentially as a result of a lack of energy efficiency labels to differentiate the products). Some end users also lack information on the costs of operating their equipment. There is thus a lack of information available to end users to enable confident and accurate assessment of the available technology options and related energy saving potentials. New equipment is often purchased only when old equipment fails, and there is no time to analyse in detail the purchase options (a particular issue for small end users). This can add to the difficulties of making an informed purchasing decision Lack of trained technicians State-of-the-art systems require newly trained technicians to operate the equipment. Stakeholders estimate that there are not enough hydrocarbons and CO 2 trained technicians to supply maintenance or installation for a large number of systems like this BIO Intelligence Service. Eco-design Preparatory Study Lot 12. Final Report prepared for DG TREN Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3 23

292 3.11. CONCLUSIONS User behaviour has a significant impact on electricity consumption and environmental performance, of commercial refrigeration equipment. Improving simple operational and maintenance practices could provide significant energy savings (within a 15% range). Reducing heat loads, refrigerant leaks, ensuring good practice in installation, use and maintenance are all important in achieving reduced energy consumption and environmental benefits. End-user barriers to eco-design have been identified and include lack of user information, cost being the main focus, and lack of financial incentives. These will need to be taken into account when focusing on improvement potential (Task 6). The user patterns identified for the product groups in this task are an important input for analysis of the products in Task 4. For service cabinets and walk-in cold rooms, the use pattern is constant (24 hours per day), in that the products are constantly providing cooling for storage, The almost constant use of remote condensing units (approximately 16 hours per day) reflects the product group s predominant use for remote refrigerated storage. Blast cabinets are used in a different way, for pre-determined cycles to pull-down foodstuff temperature (estimates of use range from 810 to 2,200 hours per day). Chillers are used intermittently, at an estimated average of 12 hours per day, during industrial and commercial processes. Barriers to eco-design related to the end user have been identified and will need to be taken into account when focusing on improvement potential (Task 6). They include lack of standardised testing, lack of financial incentives and market preference for trusted and reliable technologies over new developments. Some recommendations to improve energy efficiency of products from sustainable consumer behaviour include: testing standard to be finalised or adapted for service cabinets, process chillers and remote condensing units and developed for walk-in cold rooms and blast cabinets; these need to replicate real user behaviour as closely as possible (e.g. door openings, loading pattern, ambient conditions); good practice schemes or legislation regarding assembly and site installation of walk-in cold rooms, to avoid sub-standard, inefficient shells, and remote condensing units, to minimise refrigerant leakage; to avoid user confusion, manufacturers must provide straightforward and accurate display of internal temperature, and a temperature control mechanism, in all products; load limit indications on the cabinet/storage rooms (load limit shows the maximum filling of the cabinet/storage rooms) need to be clearly visible and understandable by the end-user; user manuals should include information on best installation, user and maintenance practices. 24 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3

293 ANNEXES Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3 25

294 Annex 3-1: Refrigeration in the medical sector The demands made on refrigeration equipment are particularly high in medical environments, where the long-term, trouble-free operation of equipment needs to be assured. As such, the most stringent reliability and safety standards apply to appliances used in both laboratories and the medical sector. These refrigerators (and freezers) allow hospitals, pharmacies and universities to store temperature-sensitive pharmaceuticals under optimal conditions. Refrigerating appliances for medical applications are in the scope of World Health Organisation (WHO) specifications. WHO performance specifications exist for the following categories of equipment: cold rooms, freezer rooms and related equipment, as well as refrigerators and freezers. Since 1979, WHO in collaboration with UNICEF Supply Division, have developed and maintained a series of performance specifications and test procedures for cold chain equipment, injection devices, and other immunisation-related products, under the PQS system (Performance, Quality, Safety). The refrigerators and freezers in the medical sector are mainly used to store blood (Blood Bank Refrigerators), vaccines, chemicals and organs. They operate at a wide range of temperatures, from -120 C to +22 C. They are also much more sensitive to temperature changes. The inner temperature measurement resolution is around +0.1 C. Additionally, mobile refrigerators exist for safe transportation of temperature sensitive chemicals, vaccines, blood and its components. 26 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 3

295 European Commission DG ENTR Preparatory Study for Eco-design Requirements of EuPs [Contract N S ] Lot 1 Refrigerating and freezing equipment: Service cabinets, blast cabinets, walk-in cold rooms, industrial process chillers, water dispensers, ice-makers, dessert and beverage machines, minibars, wine storage appliances and packaged condensing units Task 4: Technical analysis and assessment of Base Cases Final report Contact BIO Intelligence Service S.A.S. Shailendra Mudgal Jonathan Bain +33 (0) shailendra.mudgal@biois.com jonathan.bain@biois.com

296 Project Team BIO Intelligence Service Mr. Shailendra Mudgal Mr. Benoît Tinetti Mr. Jonathan Bain Mr. Raul Cervantes Mr. Alvaro de Prado Trigo Disclaimer: The project team does not accept any liability for any direct or indirect damage resulting from the use of this report or its content. This report contains the results of research by the authors and is not to be perceived as the opinion of the European Commission. The European Commission is not responsible for any use that may be made of the information contained therein. 2 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

297 Contents 4. Technical analysis and assessment of Base Cases Introduction The vapour-compression cycle: Heat transfer and efficiency Refrigerants Latent heat of vaporisation Compression ratio Specific heat of the refrigerant (both in liquid and vapour state) Use of refrigerants End-of-life disposal Product interaction with the system Factors affecting the energy consumption Operating temperature Operation: pull-down or steady-state refrigeration Ambient conditions Location of condensing unit: remote or plug-in Condenser cooling: air-cooled, water-cooled or evaporative condensation Design: packaged or bespoke Door (and drawer) configuration Internal layout Orientation Vapour-compression or absorption Individual or parallel compressor units Component technical analysis Electric motors Characteristics Shaded pole motor Permanent split capacitor motor Electronically commutated permanent magnet motor Application in refrigeration products Performance Regulation Compressor Types February 2011February 201 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 3

298 Characteristics Performance Selection Control Expansion device Capillary tube Thermostatic expansion valve Electronic expansion valve Evaporator Types Characteristics Performance Condenser Types Characteristics Performance Pumps Liquid suction heat exchanger Liquid receiver Piping system Insulated enclosure Anti-condensation heater Defrosting Compressor shutdown Electric Hot or cool gas Control systems Product technical analysis Service cabinets Product description at component level Component use pattern, energy consumption and saving potential Blast cabinets Product description at component level Component energy consumption, use pattern and saving potential Walk-in cold rooms Product description at component level Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

299 Component energy consumption, use pattern and saving potential Process chillers Product description at component level Component energy consumption, use pattern and saving potential Remote condensing units (RCUs) Product description at component level Component energy consumption, use pattern and saving potential Summary Base Case technical specifications Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units Inputs for Base Case assessment Lifecycle stages Data inputs summary Base Case environmental and economic impact assessment Service cabinets Life Cycle Costs EU Totals Sensitivity analysis Blast cabinets Life Cycle Costs EU Totals Sensitivity analysis Walk-in cold rooms Life Cycle Costs EU Totals Sensitivity analysis Process chiller Life Cycle Costs EU Totals Sensitivity analysis Remote condensing unit Life Cycle Costs February 2011February 201 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 5

300 EU Totals Sensitivity analysis Summary of environmental impacts Eco-design indicators Conclusions ANNEXES ANNEX 4-1: Sub Base Case technical specifications Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units ANNEX 4-2: Component material proportions ANNEX 4-3: Service cabinets EcoReport results and detailed BOM ANNEX 4-4: Blast cabinets EcoReport results ANNEX 4-5: Walk-in cold rooms EcoReport results ANNEX 4-6: Process chillers EcoReport results ANNEX 4-7: Remote condensing units EcoReport results Annex 4-8: Dessert and beverage machines, water dispensers and ice-makers Dessert and beverage machines Water dispensers Ice-makers Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

301 4. Technical analysis and assessment of Base Cases 4.1. INTRODUCTION The objectives of Task 4 are to: build on the product definition set out in Task 1 by describing the technical function of refrigeration and the products in scope; assess environmental improvement areas; and describe the Environmental Impact Assessment and Life Cycle Cost analysis of the Base Cases (this analysis uses data gathered from Tasks 1, 2 and 3). The refrigeration equipments identified in Task 1 are used by a wide range of users. Service cabinets, blast cabinets, and walk-in cold rooms are primarily used in restaurants, catering facilities, hotels, and supermarkets. Process chillers are more used for industrial and commercial processing. Remote condensing units used in a variety of applications, those covered in ENTR Lot 1 are mostly destined for commercial application. Task 2 described product market figures, provided insight into the current market situation, trends and structure. Finally, economic data on manufacturing costs, consumer prices and rates was provided for use in Life Cycle Cost (LCC) calculations. The results of Task 3 show that user behaviour could have a significant impact on the electricity consumption of refrigeration equipment through operational and maintenance practices. Initial technical analysis data for dessert and beverage machines, water dispensers and ice machines are provided in Annex 4-1. A preliminary analysis suggested that their figures for stock numbers, energy consumption, and energy saving potential made them less of a priority in terms of potential improvement and energy consumption reduction across the EU, compared to the products selected for further analysis. These conclusions are discussed in Task 1 and data displayed in Annex 1-2. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 7

302 4.2. THE VAPOUR-COMPRESSION CYCLE: HEAT TRANSFER AND EFFICIENCY Refrigerators and freezers work on the principle of a reverse heat engine. Figure 4-1 demonstrates that the refrigeration unit removes heat (Q1) from a low temperature source and then transfers heat (Q2) to a high temperature source using a certain amount of electrical energy input (E) for the purpose of cooling the cold region. Heat pumps do the same thing with the intent of heating the hot region. High temperature heat sink T H Q2 Refrigeration system or heat pump E Q1 Low temperature heat source T L Figure 4-1: Principles of refrigeration systems The efficiency of the refrigeration system is expressed by the COP (coefficient of performance) which is the ratio of the refrigeration effect (heat extracted) and the energy input required: Q1 COP E The purpose of the refrigeration unit is to keep the low temperature heat source at the desired temperature T L. Heat leakage from the surroundings to the low temperature heat source tends to increase this temperature. In order to keep the cold region at T L a certain amount of heat Q1 has to be removed. These heat transfers are made possible through the vapour compression refrigeration cycle, and as described in Task 1, almost all refrigerators and freezers in operation are based on this cycle. The main components in a vapour compression system are the compressor, the expansion valve and two heat exchangers referred to as evaporator and condenser. The components are connected to form a closed circuit, as shown in Figure 4-2. A volatile liquid, known as the working fluid or refrigerant, circulates through the four components. 8 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

303 cold side low pressure compressor warm side high pressure evaporator P1, T1 fan fan condensor P2, T2 Expansion device Cabinet case for plug in refrigerated cabinets and cold vending machine case Cabinet case for remote refrigerated cabinets Figure 4-2: Schematic representation of the refrigeration cycle Vapour compression system As shown in Figure 4-2, the cycle starts with a low temperature (T1), low pressure (P1) mixture of liquid and vapour refrigerant entering the evaporator where it absorbs heat from the relatively warm air surrounding the evaporator. This heat transfer, corresponding to the refrigeration effect (Q1 in Figure 4-1) boils the liquid refrigerant in the evaporator and this superheated vapour (the temperature of the refrigerant vapour is above its saturation temperature) is drawn in the compressor. Evaporator fans are used in order to increase the heat transfers. The refrigerant is superheated to prevent the formation of liquid droplets in the compressor, which would affect its operation. The compressor compresses the refrigerant into a hot high pressure refrigerant vapour which is released in the condenser. Within the condenser, the high pressure (P2 in Figure 4-2) refrigerant is condensed at high temperature (T2 in Figure 4-2) by heat transfer (Q2 in Figure 4-1to the relatively cool ambient surroundings. The condenser is often equipped with a condenser fan, used to increase the heat transfer. The condenser causes the vapour to cool down, condense into liquid and further sub-cool. A liquid receiver at the exit of the condenser serves to accumulate the reserve liquid refrigerant, acting as a stock for off-peak operation, and to permit pumping down of the system. The receiver also serves as a seal against the entrance of gaseous refrigerant into the liquid line. The refrigerant liquid then travels to the expansion device where it is reduced to a low pressure, and low temperature (T1). This pressure drop causes a small part of the refrigerant to boil off. The cooled liquid-vapour mixture then re-enters the evaporator to repeat the cycle. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 9

304 pressure 4.3. REFRIGERANTS The thermodynamic properties of the refrigerant can be plotted in a pressureenthalpy chart, as shown in Figure 4-3. The blue curve represents the saturated liquid line (on the left) and the saturated vapour line (on the right) and limits the liquid domain, the vapour domain and the liquid-vapour domain of the refrigerant. The refrigeration cycle is represented in bold black. subcooling Critical point P2 P1 Liquid expansion condensation Liquid + Vapour evaporation Vapour compression Q1: heat transferred at the evaporator (pressure P1) corresponding to the refrigeration effect Q2: heat transfered at the condenser to the heat sink (pressure P2) w: compression work superheat enthalpy Q1 IwI IQ2I Figure 4-3: Pressure-Enthalpy chart of the vapour-compression refrigeration cycle The right refrigerant selection is important for energy efficiency, as it can affect the energy consumption of the refrigeration equipment. The following thermodynamic properties of the refrigerant have significant impact on the heat transfer and therefore on the performance of the refrigeration system LATENT HEAT OF VAPORISATION High latent heat 1 of vaporisation is desirable because the refrigerant mass flow rate per unit of refrigeration effect is reduced. When a high latent heat of vaporisation is combined with a low specific volume in the vapour state, the compressor work needed is reduced, allowing the use of smaller and more compact equipment. 1 Latent heat refers to the amount of energy released or absorbed by a chemical substance during a change of state that occurs without changing its temperature, meaning a phase transition 10 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

305 COMPRESSION RATIO The compression ratio is the ratio of the absolute discharge pressure (P2 in Figure 4-2) to the absolute suction pressure (P1 in Figure 4-2). In the case of a system with reciprocating compressors, all factors being equal, the refrigerants with the lowest compression ratio are the most desirable. This results in low power consumption and high volumetric efficiency SPECIFIC HEAT OF THE REFRIGERANT (BOTH IN LIQUID AND VAPOUR STATE) High specific heat translates into good heat transfer properties. Increasing these factors will allow the use of a smaller charge of refrigerant. Therefore, in regards to thermodynamic properties, the best refrigerant would have the following characteristics: Low liquid viscosity: improves heat transfer primarily in condenser; Low vapour viscosity: reduces single-phase and two-phase pressure drops; High liquid thermal conductivity: improves heat transfer in evaporator and condenser; Low liquid density: improves heat transfer in evaporator; High vapour density: improves heat transfer in condenser and reduces pressure drops; High latent heat of vaporisation: reduces evaporator and condenser pressure drops; High liquid specific heat: improves heat transfer in evaporator and condenser; Low saturated temperature-pressure gradient: reduces compression ratio and therefore compressor power consumption; Volumic refrigerating effect (latent heat divided by specific volume): an important (but not absolute) indicator of the effect of refrigerant properties on the efficiency of a real refrigeration system. Figure 4-4 shows the variation of some of the selected properties listed above with molecular mass of the fluid (based on mass fraction in the case of mixtures) for a lot of refrigerants, where the properties were calculated for 0 C using the Refprop database 2. A limited number of common refrigerants are indicated. Refrigerants with a lower molecular mass such as ammonia (R 717) and propylene (R 1270) are shown to have favourable thermodynamic properties, thus higher efficiency. The desired thermodynamic properties are a boiling point below the target temperature, a high heat of vaporization, a moderate density in liquid form, a relatively high density in gaseous form, and a high critical temperature. However, R1270 is said to be a very unusual refrigerant in commercial refrigeration and it is not viable for general use 3. 2 Lemmon et al, Source: Defra Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 11

306 Figure 4-4: Variation of refrigerant thermodynamic properties 4 Currently the main refrigerants used in the refrigeration sector are hydrofluorocarbons (HFCs) R134a and R404A Refrigeration equipment is also being adapted to also allow use of other refrigerants, such as hydrocarbons (HCs) isobutane (R600a) and propane (R290). Although HCs have a much reduced GWP, their disadvantage is flammability, in that sufficient leakage could lead to an explosive mix of gases if leakage occurs in enclosed spaces. Components such as electric motors 5 have been developed to avoid this occurring due to component sparking. The use of other natural refrigerants is also being proposed as a means to reduce the direct environmental impacts of refrigeration systems (due to refrigerant leakage), as well as enabling energy savings through improved refrigeration system performance. However, such systems sometimes have drawbacks. Some alternative refrigerants are not efficient in particular conditions, for example high ambient temperatures for CO 2 (R-744) systems. Hence, they are more prevalent in specific countries, such as Denmark and Sweden. Besides that, the main drawback of R744 is the transcritical operation. Sensible heat rejection occurs above the critical point at constant pressure, resulting in gliding temperatures. Therefore, unlike subcritical systems, the refrigerant is not condensed by normal condensers or heat exchangers but cooled by gas coolers 6. Other refrigerants have charge limitations due to safety requirements. However, alternatives already exist in the market, and future developments will diversify the variety of refrigerant choices. However, the choice of the appropriate refrigerant is a compromise between its environmental, thermodynamic and safety properties. Environmental and safety data of several refrigerants used in refrigerated systems are presented in Task 5, including parameters such as flammability. A good comparison of environmental 4 Reference: BNCR37: Characteristics of refrigerants in relation to efficiency, Market Transformation Programme efficient-products.defra.gov.uk/spm/download/document/id/702 5 Source: Ebm-papst Landshut 6 Colombo et al.: Case study R744: A transcritical system with heat recovery for a supermarket. 12 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

307 and efficiency properties can be done using TEWI (Total Equivalent Warming Impact) values. However, the safety information of refrigerants should follow the standards ANSI/ASHRAE 34 7, EN 378-1:2009 or ISO 817. The ANSI/ASHRAE standard has been suggested by manufacturers to classify refrigerants in terms of safety. However, it is not completely harmonised to the EU Directives, and some stakeholders suggested that it is too restrictive for most of the natural refrigerants. These classifications and assessment of each type of refrigerant are further explained in the analysis of refrigerants in Task 5. Some substances that can be used as refrigerants are also used as foaming agents in insulation materials in refrigeration products. A foaming agent is usually a surfactant that strengthens the foam, and some HFC blends are developed specifically for that function, as HFC-245fa. However, the environmental impacts of this HFC used as foaming agents are expected to be lower than the impacts caused by refrigerants, because they are not supposed to be emitted throughout leakages, and the quantity used in the products is lower, but no independent study has been found to prove this statement USE OF REFRIGERANTS The global warming potential of refrigerants is characterised by the GWP indicator (global warming potential). Other alternatives exist, to avoid the use of HFCs, such as the use of hydrocarbon or carbon dioxide. Experience has shown 8 that, in certain ambient conditions, refrigeration systems running with HC and carbon dioxide can achieve the same levels of efficiency as HFC based systems. For example, the coefficient of performance of compressors running with hydrocarbons is generally slightly better than compared to HFC systems due to better thermodynamic properties (particularly R290 and R1270, even though the latter is a very unusual refrigerant in commercial refrigeration). When comparing the GWP of systems running with different types of refrigerant, the global warming potential is often characterised by the TEWI, Total equivalent Warming Impact, which also takes into account the emissions of greenhouse gases due to the electricity consumption of the system. These two environmental impacts (Global warming potential and Ozone depletion potential) are not only an issue if the refrigerant leaks or if the treatment is not appropriate at the end-of-life stage, but also during the production phase. Some of the key requirements to reduce environmental impacts are the reduction of refrigerant charges and the control during use. The F-Gas Regulation EC 842/2006 requires the recovery of HFC refrigerants during service, and at end-of-life. It establishes standard inspection requirements and indirect and direct leakage measurements for refrigeration systems (among others). These issues and others associated to refrigerants are further explained in Task 5. 7 No equivalent standard in the EU; the International Institute of Refrigeration recommended use of this standard 8 Feedback from the Refrigerants, Naturally! initiative Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 13

308 END-OF-LIFE DISPOSAL Plug-in refrigerators and freezers can be handled like household equipment. The RAL association, specialised in demanufacturing of refrigeration equipment containing CFCs, has been working on a certification for recycling plants which includes the following steps: Step 1: extraction of refrigerant. Step 2: extraction of the insulating foam and other components containing harmful substances. Step 3: separating, sorting and classification of the material obtained in step 1 and 2 and preparative steps needed to the re-use, and/or disposal of these materials. After the treatment of harmful substances, the compressor, in the case of a plug in, is withdrawn and handled separately. The rest of the appliance is then ground in order to segregate ferrous and non-ferrous metals, along with plastics. The metallic part is removed with a magnet, and will be re-used in new products. About 85 % of materials (metals and plastics) included in the appliance are recycled. Moreover, about 10 % of materials (only plastics) are burned in order to recover the heat created, and only 5 % of plug in and remote equipment is thrown away in landfills. 9 Concerning refrigerant end-of-life, data has been collected from different studies and from the EFCTC (European Fluorocarbon Technical Committee). The F-Gas Regulation EC 842/2006 requires the recovery of HFC refrigerants during service, and at end-of-life. In addition, the WEEE directive requires end-of-life recovery and treatment of CFCs, HCFCs, HFCs or other gases that are ozone depleting or have a GWP higher than 15. EFCTC member companies offer recycling and destruction (typically incineration) schemes directly or via their distributors for HFC refrigerants. The HFC refrigerant currently returned to suppliers is relatively small and the percentage of recycled refrigerant returned to supply chain by HFC producers is small. Refrigerant recycling can extend the product s lifespan to 15 years. Typically, the second hand refrigerant would be reclaimed and supplied to the same specifications as a virgin refrigerant. Recovery/recycling machines allow engineers to reuse HFC without returning them to the suppliers. Because refrigerants are simple to be treated locally, a significant proportion of the recovered refrigerant is treated in this way, although practice varies by country. EFCTC comments that it is expected that the WEEE directive will impact on the quantity of refrigerant recovered at end-of-life. In plug-in products, the refrigerant charges are small (0.2 1 kg) but end-of-life recovery is almost non-existent Estimations from manufacturers 10 IPCC Special Report on Safeguarding the Ozone Layer and the Global Climate System. Chapter 4 Refrigeration. (2005) 14 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

309 4.4. PRODUCT INTERACTION WITH THE SYSTEM This section discusses the interaction of individual products within their environment and system. For plug-in equipment all components are integrated in the product. In the case of plug-in products, the functional system consists of: the product itself; its surroundings; and the control system(s). Plug-in product The control systems Surroundings Ambient temperature Ambient humidity Figure 4-5: Functional system for plug in refrigeration appliances Remote appliances are not used as stand-alone products, and they also interact with their surroundings as well as with the building s air conditioning and heating system. They receive refrigeration energy from a remote condensing unit, as shown below. Indoor conditions Ambient temperature Ambient humidity The control systems Outdoor conditions Ambient temperature Ambient humidity Remote product Case Evaporator Evaporator fans Expansion device Others Refrigeration circuit Direct expansion Indirect expansion Direct expansion distributed Cascade Condensing unit Compressor Condenser Condenser fans Figure 4-6: Functional system of remote refrigeration appliances For remote appliances the evaporator, the refrigerant and the expansion device are the only components included in the equipment and the compressor and the condenser are located outside of the product. The functional system of remote products includes: the product itself (including accessories e.g. defrost heaters); the ambient surroundings of the product (e.g. temperature, humidity); the different regulating systems; other equipment linked to the same refrigeration system; and the refrigeration system (remote condensing unit), via the refrigerant piping circuit. Large, central refrigeration systems (central plants, racks and packs) are discussed in a separate technical annex to this report. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 15

310 4.5. FACTORS AFFECTING THE ENERGY CONSUMPTION Energy consumption is mainly dependent on the hours of use, operation and ambient temperatures, capacity, and efficiency of a product s components. As these parameters are considered in the product analysis (the study compares products with the same functional unit), this section compares a range of different technical options that might affect energy efficiency or environmental performance of the products, including those factors that affect products with the same function, use patterns and capacity OPERATING TEMPERATURE Relevance: Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units The refrigeration load which needs to be delivered by the compressor depends on the desired temperature inside the refrigeration appliance. The lower the operating temperature is, the higher the demand for cooling load, and the higher the electricity consumption. Moreover, defrost heaters used in cabinets and cold rooms working at low temperatures represent additional electricity consumption and an additional heat load within the equipment. According to information provided by stakeholders, most of the characteristics of the products, including refrigerant used, except power input and energy consumption, are similar for low and medium temperature ranges. According to the opinion of some experts, the power input for those products operating at low temperatures is around 40% higher than the products for medium temperatures, and for the same cooling capacity, the product is around 20% bigger 11. According to literature, typical differences between freezing and refrigerating service cabinets can be around two to three times higher. For blast cabinets, the extra energy consumption presented by freezing cycles, respect the same equipment chilling cycle, is estimated to be approximately 2.5 times higher. In remote condensing units and chillers, the increase in energy consumption of appliances working at low evaporating temperatures is around 1.7 times the consumption of medium temperature products OPERATION: PULL-DOWN OR STEADY-STATE REFRIGERATION Relevance: Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units The refrigeration system of products will be designed to fit its operational requirements. One important distinction is that of pull-down cooling, compared to 11 Source: Expert estimate 16 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

311 steady-state cooling for storage. A blast cabinet, for example, will have a powerful refrigeration system (considering its capacity), and requires this to rapidly bring down the temperature. However, a product designed to provide steady-state cooling will not perform well if required to rapidly pull-down temperature. In addition, a pull-down system will not perform efficiently if required to store produce at a steady temperature (as its refrigeration system is unnecessarily powerful for this task) AMBIENT CONDITIONS Relevance: Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units The temperature and humidity in which a product and its condensing unit are located affect the heat infiltration into the product housing (and hence increased heat load), the work required to remove the heat from the condenser (a reduced temperature difference between the condenser and air increases energy consumption, or lower ambient temperature increases heat transfer from condenser), and the frosting on the evaporator (potentially reducing heat transfer and increasing defrost duty). As many of the product groups are located indoors, at relatively high temperature (e.g. in professional kitchens), remote condensing can take advantage of lower ambient temperatures outdoors. Due to varying climates in EU, and varying indoor conditions where products are located, the performance of products may differ. Often equipment is designed to operate at a worst case scenario of high ambient temperature. If this occurs, then the product will effectively work at part load for a significant portion of the year (when worst case conditions are not met). However, standards for chillers and condensing units in particular do not take into account this requirement for most products to operate at part load, or operate at differing temperatures from the norm. Hence, they may not accurately reflect real use. According to members of the chillers and condensing unit industry, the machines do not work at full load more than 20% of their running time. The rest of the time, the machines can decrease their load to even less than 50%. Some stakeholders have mentioned that the average work capacity during a year could be 40% of the full load capacity, depending on environmental conditions and cooling requirements. This is the reason why the season and partial load conditions should be considered during the evaluation or testing of these machines. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 17

312 LOCATION OF CONDENSING UNIT: REMOTE OR PLUG-IN Relevance: Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units * * Remote configuration for service cabinets is extremely rare in the market. The compressor and the condenser can either be integrated in the product (plug-in units) or located in a remote location (remote units). In the case of remote products, the condenser is often located on the rooftop or outside of the building where the product is used. Having more space around the condenser provides a better heat exchange with the environment. Depending on the difference between internal and external ambient temperatures, the efficiency of remote compared to plug-in equipment can vary. Lower ambient temperatures increase the heat transfer from the condenser. Based on the findings of the preparatory study to TREN Lot 12, and on qualitative analysis, it is estimated that plug-in products usually present higher energy consumption than remote products 12. Other explanations for lower energy consumption of remote products could include: larger condensers can be used since there are less space restrictions than in plug-in units. As described in , a large surface area of the condenser allows greater heat exchange. Remote products could alternatively use water-cooled or evaporative condensers, which both present higher efficiency than the smaller air-cooled condensers, used in plug-in units 13. in the case of remote central refrigeration systems, the cooling load of compressor is shared by the different refrigerant equipments connected to it, including the remote cabinet. This optimises the compressor duty cycles, thus reducing the power demand of the system. due to the fact that many of the products covered in ENTR Lot 1 are located in professional kitchens, where internal ambient temperatures are often high, remote systems may benefit from lower external ambient temperatures. However, remote units (especially supermarket packs) are in some cases maintained at condensing temperatures higher than those that can be achieved in internal ambient temperatures typical of comfort conditions in a populated space. In addition, while a refrigeration system served by a remote condensing unit has a net cooling effect on the internal environment, which may require supplementary heating, the opposite is true of integral units which provide a net heat gain to the internal environment. This is because all heat removed from the refrigerated space 12 Source: Mark Ellis & Associates. Minimum Energy Performance Standards for Commercial Refrigeration Cabinets. EECA Energy efficiency and Conservation Authority, June Source: UK Catering Equipment Suppliers Association (CESA) 18 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

313 plus that of the heat-generating components located externally of the refrigerated space is rejected locally. One significant trade-off of remote systems is the potential increase in refrigerant leakage, compared to plug-in units. As remote systems are installed on-site, the level of workmanship may not reach the same quality of that achieved in dedicated manufacturing lines used to produce plug-in units, hence there may be increased leaks due to faulty piping connections CONDENSER COOLING: AIR-COOLED, WATER-COOLED OR EVAPORATIVE CONDENSATION Relevance: Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units * *(water-cooled and evaporative for remote condensing and process chillers only) Air-cooled condensers are most commonly used, and require a greater surface area compared to water-cooled units, but are not subject to freezing or water problems; however, they may eventually be subjected to air corrosion problems. Air-cooled condensers also generate noise due to the operation of the fans, which can be an issue if disturbing neighbouring residences in urban areas. According to the opinion of some experts, air-cooled process chillers generally consume between 10 and 30% more power than a water-cooled unit, as a wet surface will transfer heat better than a dry surface. Water-cooled chillers generally require cooling towers, including piping and energy-consuming pumps. Water-cooled condensers can be relatively small compared to air-cooled, due to the better heat transfer properties of water compared to those of air. However, water may be scarce or chemically unsuited for condenser cooling use. In addition, water-cooled condensers are subject to additional cost and need for water, and are at risk of scale, fouling, freezing, corrosion if water is in contact with outside air (relevant for open or semi-open water circuit), potentially dangerous bacteria, and biofilms. However, in the case of dry-cooled water condensers, there is no contact between water and air. Evaporation-cooled condensers use a mist of water in combination with air to improve the heat transfer. The performance of these systems is better than that of air-cooled, but less than water-cooled DESIGN: PACKAGED OR BESPOKE Relevance: Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units This topic is related to installation, which can affect product efficiency. As with remote compared to plug-in products, packaged and bespoke products can have varying levels of build quality. Bespoke units are often field-erected, which may Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 19

314 affect refrigerant leakage if pipework is poorly constructed. Packaged units constructed on production lines are considered on average to have a higher build quality, and hence are likely to have lower levels of refrigerant leakage. However, packaged products can often be installed by non-experts, due to the refrigerant being pre-charged. This lack of expertise may lead to inaccurate set-up for the required use, leading to reduced efficiency and higher energy consumption DOOR (AND DRAWER) CONFIGURATION Relevance: Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units The type, size and number of doors (and drawers for service cabinets only) are important criteria determining the performance of products. This is due to their impact on the spillage of cold air from the product to the external environment, and inflow of warmer external air into the product, and also the transmission of heat from the external environment through the door and round its edges. For example, every time doors are opened in service cabinets, the cooling load demand increases, due to cold air spillage and heat transfer from the surroundings. Drawers and/or half-doors are often advertised as enabling energy savings because they allow reaching for items in the service cabinet without exposing the entire refrigerated volume to the ambient atmosphere (unlike single larger doors) 14. However, at this stage, no data was found to support such a statement INTERNAL LAYOUT Relevance: Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units The products covered in ENTR Lot 1 use forced air cooling, with fans forcing the cold air from the evaporator throughout the internal volume to regulate temperature (as opposed to static cooling which uses natural convection). As shelves are used to hold items inside the products, the internal layout can significantly affect the airflow from the evaporator, and a poor design of the interior shelf configuration can therefore disrupt the flow of cooled air through the product, and reduce the overall performance. 14 Source: Caterer and Hotel Keeper, 12 October Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

315 ORIENTATION Relevance: Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units Orientation could also affect the energy consumption of service cabinets, as different air-flow patterns are achieved from the inside of the cabinet to the outside of the cabinet. Depending on the cabinet s orientation (vertical, chest or horizontal), the air flow pattern is altered. This affects: the air flow inside the cabinet s insulated casing; and the quantity of cold spillage when opening the service cabinet. The cold spillage can be different depending on the door configuration, with horizontal chest cabinets typically being less subject to such losses. However, no quantified data is available at this stage VAPOUR-COMPRESSION OR ABSORPTION Relevance: Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units Due to the refrigerant used and the refrigeration cycle, an absorption chiller is less efficient than a vapour compressor refrigeration cycle. To operate absorption chillers a heat source such as steam or hot water is needed. This source can be generated by a boiler or waste heat can be used. In general, the cycle, where the heat source has higher temperature, is more efficient. However, there are some limitations due to technical issues as corrosion protection for example. Due to these technical differences, and only to provide indicative figures, the recommended energy performance levels for air-conditioning chillers as per the US ASHRAE Standard are as follows: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 21

316 Table 4-1: Performance levels for chillers used for air-conditioning according to ASHRAE table C Chiller Capacity (RT refrigeration ton) COP IPLV Air cooled electrical All Air cooled w/o condenser All Water cooled Reciprocating All < 150 RT Water cool screw rotary and 150 RT and < 300 RT scroll 300 RT < 150 RT Water cool Centrifugal 150 RT and < 300 RT RT Air cooled absorption single effect All 0.60 Water cooled absorption All 0.7 Absorption double effect indirect fired All Absorption double effect direct fired All *COP Coefficient of Performance *IPLV Integrated Part Load Value The absorption chiller has very low efficiency versus vapour compression cycle (3 to 6 times less efficient), however benefits from the fact that it does not use electricity to drive the refrigeration cycle. Electricity is a high value energy form (with its own inherent inefficiencies such as generation and transmission losses) and vapour compression exclusively requires electricity. Absorption chillers typically use low grade heat or waste heat to drive the refrigeration cycle, partially avoiding electricity use INDIVIDUAL OR PARALLEL COMPRESSOR UNITS Relevance: Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units *remote condensing in for all the products Using one compressor on several fixtures results in the greater efficiency of compressor motors, because they are larger. Besides, more heat can be captured from the equipment for heating the space or for heating water. The disadvantages of that product are as follows: the refrigeration load cannot be closely matched; starting and stopping larger compressors is harder; short cycling larger compressors may increase both electrical demand and consumption charges; and larger compressors are more sensitive to refrigeration load. On the other hand, using parallel compressor units (to apply two or more compressors to a common suction header, a common discharge header and a 22 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

317 common receiver) results in the potential for more effective load matching. Compressors are subsequently turned on or off in response to the changing load. Other advantages are diversification, flexibility, higher efficiencies, lower operating costs and less compressor cycling. The drawback of this kind of system is that any leaks affect the entire compressor rack 15. Although the use of parallel compressors is possible for bigger blast cabinets, those included within the scope do not commonly include this feature. Tomczyk 15 Refrigeration & air conditioning technology Par William C. Whitman, William M. Johnson, John Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 23

318 4.6. COMPONENT TECHNICAL ANALYSIS The performance of the refrigeration system depends on the components it includes. This section describes the different components found in refrigeration equipment ELECTRIC MOTORS Characteristics There are a variety of types and sizes of motors, depending on the application requirements. The power range of motors used in the refrigeration sector is mainly between 0.3 to 2,000kW and they are responsible for the 33% energy consumption used in the refrigerator sector 16, although for products in the scope of ENTR Lot 1, motors under 300W are often used. Start-up type Single-phase induction motors require separate starting windings to assure proper start rotation and sufficient starting torque. The type of start-up differentiates the three main types of single phase induction motors, which include the shaded pole motor, the permanent split capacitor motor (PSC), and the electronically commutated permanent magnet motor (ECM). Direct and alternating current Both DC (Direct Current) and AC (Alternative Current) electric motors can be used for refrigeration applications. Higher efficiency fan motors reduce energy consumption by requiring less electrical power to generate motor shaft output power; efficiency of the motor can be calculated in percentage, via dividing power output by power input. AC motors are in general simple and cheaper than equivalent DC machines, they do not have commutator, slip rings or brushes. The stator winding in connected to the AC source and the induction produces the currents in the rotor. Motor controls are devices that monitor the speed of a fan motor (it can be two speeds or more). Therefore, they control its efficiency indirectly as well as energy efficiency. They are usually made out of several blocks of sensors and electronic circuits which physically modulate the power to modify speed. Variable speed drive During the past several years, variable-speed-drive (VSD) for compressors and heat exchanger fans has become an option for manufacturers of refrigeration equipment. However, this option has not been commonly applied to some refrigeration equipment like blast cabinets due to their intensity of use. This type of equipment stops the blast chilling/freezing cycle when the food temperature is lower than a specific level. According to industry stakeholders, this option might have positive impacts in the energy consumption, but they are not currently applied to small machines like blast cabinets. 16 Cold Hard Facts, prepared by Energy Strategies in association with Expert Group, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

319 DC motors allow modulating the frequency of the power input and thus the rotation frequency of the motor and are much easier to control than single phase AC motors, for which a current converter is needed. Modulation of the VSD motor is achieved in two ways; through varying the frequency of the applied waveform to the motor windings, or varying the peak voltage of the waveform applied to the motor windings. These two parameters allow for control over the torque and speed of the motor at any operating condition. Inverter systems control the rotational speed of an AC electric motor by controlling the frequency of the electrical power supplied to the motor and generally consist of an AC motor, a controller and an operator interface. The conversion losses from AC to DC and back can be up to 5% per step, even though these have been reduced significantly recently. An example of a voltage varied waveform is given with the clipper. The clipper is a device that limits the voltage without affecting the rest of the waveform. It can be made of resistors, connection of diodes or transistors. Figure 4-7: Voltage clipping mechanism demonstrated on a sine waveform Shaded pole motor The shaded-pole induction motor is a single-phase motor. In a shaded-pole motor, the starting windings are shaded by a copper loop. The interactions between the magnetic field generated by the shaded portion and that generated by the unshaded portion induce rotation when the motor is powered. The imbalance between the shaded and un-shaded portions of the magnet remains throughout operation. As a result, shaded-pole motors used in commercial refrigeration applications, with low output power, are inefficient. Shaded-pole motors are, however, electrically simple and inexpensive Permanent split capacitor motor In a PSC motor, a smaller, start-up winding is present in addition to the main winding. The start-up winding is electrically connected in parallel with the main winding and in series with a capacitor. At start-up, the interactions between the magnetic field generated by the start up winding and that generated by the main winding induce rotation. Because of the capacitor, however, the current to the start-up winding is cut off as the motor reaches steady state. Because of this, PSC motors are more energy efficient than their shaded-pole counterparts. Like Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 25

320 shaded-pole motors, PSC motors are produced in large quantities and are relatively inexpensive 17. These motors are more suitable for continuous use systems, since they cannot provide an initial boost and they have low torque (30 to 150% of the rated load). PSCs have lower starting currents than split-phase motors 18 (less than 200% of the rated full-load current). These are categorized as very good equipment for high cycle rate applications 19. The advantages of PSCs are that: they are designed for high efficiency and high power factors at rated load; due to their increased efficiency compared to standard shaded pole motors, the PSCs used within a refrigerated enclosure release less heat, and therefore reduce the relative heat load that must subsequently be removed by the refrigeration system, reducing system energy consumption (see Figure 4-9); and they do not require a starting switch, which makes them more reliable. The common applications for this equipment are: direct drive fans, blowers with low starting torque requirements and intermittent cycling applications with reversing requirements Electronically commutated permanent magnet motor ECM is a high efficiency programmable brushless DC motor using a permanent magnet motor and an electronic speed controller. It is more energy-efficient than either shaded-pole or PSC motors, but ECM motors are more complex than either shaded pole or PSC motors, particularly for commercial refrigeration applications, because they are internally powered with DC power. In ECMs, the electromagnets do not move and the brush-system assembly normally used to invert the magnetic polarity is replaced by an electronic controller. A power supply is required to convert from AC line power to DC, and control electronics are required to handle the electronic commutation, i.e. switching the power to the motor windings in synchronization with motor rotation. For this reason, ECM motors can weigh more than shaded pole or PSC motors, and they are more expensive. The cost of ECMs can be up to 2.5 times higher, and the high price of ECM technology for compressors makes it advantageous only for capacities over 10kW. This depends on the total price of the product and the energy savings provided 20. They are still customised without suitable standards to allow a commodity market to develop. The mass production for specialised 17 Arthur D. Little Inc, Energy Savings Potential for Commercial Refrigeration Equipment, US DOE, A single-phase motor that consists of a running winding, starting winding, and centrifugal switch. The reactance difference in the windings creates separate phases, which produce the rotating magnetic field that starts the rotor For example, for a remote condensing unit for commercial refrigeration below 10 kw, the use of an ECM in the compressor can increase the price of the product by 20%, and can achieve energy savings of up to 10%. 26 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

321 applications has lowered their cost 21 and they may become a common component in low-power compressors. For example, ECM motors are used for compressors in small mobile cooling appliances. Although their numbers are low and price high, this provides evidence of the potential future applicability of this kind of motor to small compressors. These options are further investigated in Task 5. In addition to direct energy savings achieved through their high efficiency, ECM motors used within a refrigerated enclosure release less heat, and therefore reduce the relative heat load that must subsequently be removed by the refrigeration system, further reducing system energy consumption (see Figure 4-8 and Figure 4-9). ECMs are also easier to control than single phase shaded-pole AC motors. Stakeholders have claimed that ECMs provide twice the life expectancy of small shaded-pole motors. Figure 4-8: Comparison of the efficiency of two types of fan motors 22 Figure 4-9: Comparison of the power consumption of types of fan motors Application in refrigeration products Fans in the region of 10 to 20W typically use shaded pole motors, whereas fans above 40W normally use PSC motors; ECM motors are commonly available up to approximately 40W, with most in the range of 10 to 12W (these are increasingly used in refrigerated display and service cabinets due to significant potential to 21 EUP TREN Lot 11 Motors Final Report. February Source: Puget Sound Energy 23 Source: ebm-papst Landshut GmbH Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 27

322 reduce heat load, energy consumption and hence energy costs) 24. Ranges of motor power typically used in the fans integrated in products covered by ENTR Lot 1 are described in Table 4-2. Table 4-2: Electric fan motor power ranges, types, efficiencies and applications 25 Electric motor power Typically used in the Efficiency (%) range (W) following product: 5-70 AC Service cabinets, walk-in 5-70 ECM DC cold rooms AC ECM DC Blast cabinets, walk-in cold 500-2,000 AC rooms, RCUs, chillers 500-2,000 ECM DC Table 4-3Error! Reference source not found. describes typical power ranges for motors used in different types of compressors. Table 4-3: Electric motor sizes used in compressors 26 Power range of motor (W) Compressor type ,500 Hermetic reciprocating 3,500 53,000 Hermetic scroll 1,800 90,000 Semi-Hermetic reciprocating 8, ,000 Open reciprocating 84,000 1,905,000 Open screw 84,000 1,905,000 Semi-hermetic screw Performance As described, efficient fan motors reduce energy consumption by requiring less electrical power to generate motor shaft output power. A further comparison of motor efficiencies is provided in Table Source: Remco 25 Adapted from: Mark Ellis, In from the cold Strategies to increase the energy efficiency of nondomestic refrigeration in Australia & New Zealand 26 Mark Ellis, In from the cold Strategies to increase the energy efficiency of non-domestic refrigeration in Australia & New Zealand 28 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

323 efficiency Table 4-4: Efficiency data for types and power outputs of motors 27 SPM PSC ECM Power output (W) Power input (W) Thermal Efficiency (%) Power input (W) Thermal Efficiency (%) Power input (W) Thermal Efficiency (%) From Table 4-4, a relationship between the efficiency of the motor and the power output can be set up as shown in Figure y = 3,0433Ln(x) + 65,177 R 2 = 0, y = 8,2943Ln(x) - 0,8938 R 2 = 0,9324 y = 7,4849Ln(x) + 25,821 R 2 = 0, Output (W) ECM PSC SPM Log. (ECM) Log. (PSC) Log. (SPM) Figure 4-10: Comparison of the efficiency to power output of shaded pole (SPM), permanent split capacitor (PSC) and electronically commutated (ECM) motors This demonstrates the significant difference in the efficiencies of the three motor technologies, and suggests that the rate of decline in efficiency of shaded pole and PSC motors is greater compared to that of ECM as fan power decreases from around 25W Regulation CE marking for electric motors sold onto the EU market is managed through selfcertification, hence testing is reliant on the manufacturer. 27 Navigant Consulting, Energy Savings Potential and R&D Opportunities for Commercial Refrigeration (2009) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 29

324 As discussed in Task 1, Ecodesign requirements for electric motors have been developed in the framework of the Ecodesign Directive 2009/125/EC based on the TREN Lot 11 preparatory study 28. Minimum efficiency requirements have been established for electric motors in Commission Regulation (EC) No 640/2009 of 22 July 2009 implementing Directive 2005/32/EC of the European Parliament and of the Council with regard to ecodesign requirements for electric motors 29. Electric motors used as external power source for semi-hermetic and open compressors are sold separately and thus are covered by the Commission Regulation (EC) No 640/2009 and are not analysed in the ENTR Lot 1 preparatory study. The regulation is, however, not applicable to electric motors completely integrated into other products, such as hermetic compressors, and only covers three-phase motors from upward of 750W (motors within the scope of ENTR Lot 1 are frequently single-phase and have low power input). However, fans are under consideration for separate regulation, as discussed in Task 1, for powers from 125W upward, including those fans integrated into other products. This will therefore cover some of the fans integrated into products covered in ENTR Lot 1, but not those fans with power below 125W, which are often used for evaporator and condenser fan-coils. Hence, a gap in current and foreseeable regulation exists for these small singlephase motors and fans incorporating them COMPRESSOR The compressor receives the refrigerant coming from the evaporator, at low pressure and low temperature, compresses it, and pumps it on towards the condenser at high pressure and high temperature. The compressor efficiency is expressed in terms of Coefficient of Performance (COP), which is the ratio of the cooling load divided by the compressor power. This value can be compared to the cooling system s carnot efficiency (or COP carnot), which is the system s theoretical maximum possible COP. The COP carnot is defined as the evaporating temperature divided by the temperature difference between the evaporating and condensing temperatures, in K. 28 TREN Lot 11 Website: 29 COMMISSION REGULATION (EC) No 640/2009 of 22 July 2009 implementing Directive 2005/32/EC of the European Parliament and of the Council with regard to ecodesign requirements for electric motors 30 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

325 Types Compressors can be divided into two categories according to the compression type: positive displacement compressors and dynamic compressors. In commercial refrigeration positive displacement compressors are used. Figure 4-11: Types of compressors Positive displacement compressors confine successive volumes of refrigerant within a closed space in which the pressure of the fluid is increased by decreasing the volume in which the refrigerant is contained. Reciprocating, screw, and scroll are common positive displacement compressors. Figure 4-12: Classification of positive displacement compressors Dynamic compressors use rotating vanes or impellers to impart velocity and pressure to the refrigerant. Centrifugal compressors are the most popular compressors of this category. Other dynamic compressors include axial types; however these are not used in commercial refrigeration applications. Another way to classify compressors is based on the motor configuration: In an open compressor, the compressor motor and the compressor are in separate casings. Such configuration allows easy access to the components Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 31

326 for maintenance. However, this open architecture often results in refrigerant leaks. This type of configuration is only used in remote refrigeration systems. When ammonia is used as the refrigerant, an open compressor is the only solution because the refrigerant could have a corrosive effect on the copper contained inside the motor if sealed completely. In a hermetic compressor, the motor and compressor are located in a closed space, which allows tightness against refrigerant leakages. In this kind of compressor, the refrigerant is used to cool the motor. These compressors are mostly used for small and medium power ranges (less than 40 kw 30 ). A semi-hermetic compressor has motor and compressor assembled together, with possible access to key parts such as valves and connecting rods. In comparison with open compressors, they have an improved tightness but it is not absolute as in hermetic compressors. As in the case of hermetic compressors, the refrigerant is used to cool the motor. The main types of compressors used in commercial refrigeration equipment are hermetic reciprocating (piston) and scroll, with some screw compressors used in large machines. Rotary vane compressors are not used in commercial refrigeration equipment, this type of compressors is used mainly in air conditioning systems. Figure 4-13 shows the main compressors used in commercial refrigeration. Figure 4-13: Types of compressors: scroll, screw, rotary vane and different reciprocating (piston) 31 Reciprocating compressors are positive displacement compressors; an electric motor is driving the crank gear and moving pistons to compress and release the gas. Semi-hermetic reciprocating compressors are used in higher cooling capacities and can achieve higher efficiencies than hermetic reciprocating compressors Table 4-5 provides power ranges typically available for different types of compressors. 30 Source: Hydro Québec, Guide technique, systèmes de compression et de réfrigération, Jürgen Süβ, Impact of refrigerant fluid properties on the compressor selection. 32 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

327 Table 4-5: Range of refrigeration power according to the type of compressor 32 Type of compressor Range of use Reciprocating hermetic Up to 60 kw Reciprocating semi-hermetic Up to 500 kw Reciprocating open Up to 1,200kW Scroll Up to 100 kw Screw 20kW up to 1,200kW NB: Several compressors with different cooling capacity can be set in parallel However, it should be noted that these ranges are flexible (see Figure 4-14), and no reciprocating compressors with capacity higher than 200 kw have been found in the market. Besides that, the evaporating temperature is also important for the capacity needed in a compressor in order to be operative. For negative evaporating temperatures, i.e., hermetic reciprocating compressors are only used up to 5.7 kw, scroll compressors up to 10 kw and semi hermetic compressors can be used to achieve higher cooling capacities 33. Figure 4-14: Approximate capacity ranges for compressors 34 Most plug in refrigerated service cabinets and blast cabinets use hermetically sealed, electric motor driven compressor units with a reciprocating compressor. Open or semi-hermetic compressor units are commonly used for remote refrigeration systems. Figure 4-15 shows the internal elements of a typical hermetic reciprocating compressor. 32 Reference: Direction générale des Technologies, de la Recherche et de l Energie (DGTRE) du Ministère de la Région wallonne 33 Source: Bitzer 34 Source : Refrigers.com Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 33

328 Figure 4-15: Cutaway diagram of a hermetic reciprocating compressor Characteristics Table 4-6 gives an overview of the main characteristic values of compressors depending on the type of appliance (plug in compared to remote) 35. The following data are assessed at the following rating points, including Suction Gas Temperature (SGT): low temperature: Evaporating -35 C / Condensing +40 C / SGT +20 C / Subcooling 0 K; medium temperature: Evaporating -10 C / Condensing +45 C / SGT +20 C / Subcooling 0 K. Type of Appliance Self-contained (R404A Remote (R404A) Table 4-6: Overview of compressor characteristics Feature Range LT MT Cooling capacity range 0.5 to 2.0 kw 0.8 to 4.0 kw Nom. COP Range 0.9 to to 2.0 Average COP Cooling capacity range >3 kw >8kW Nom. COP Rang 1.10 to to 2.37 Average COP As can be seen in the table above, the COP is higher for medium temperatures which means that compressors perform better at these temperature ranges rather than at low temperatures. Moreover, capacity ranges affect performance of compressor and in general compressors are more efficient in bigger capacity ranges as well as in remote appliances. It has to be noted that differences between 35 Tested to standard EN Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

329 Performance cooling capacity ranges for LT and MT appliances in this table might be due to dimensions of products (different net volumes) and so the cooling capacity ranges do not represent the energy consumption. In typical screw compressor-based refrigeration systems, compressor lubricant may comprise on the order of 10% by weight of the compressed refrigerant gas discharged from the compressor and, despite the availability and use of 99.9% efficient oil separators, 0.1% of the lubricant available to a screw compressor is continuously carried out of the compressor-separator combination and into downstream components of the refrigeration system. The lubricant typically makes its way to the low-side of the refrigeration system and concentrates in the system evaporator. The low-side of a refrigeration system is the portion of the system which is downstream of the system expansion valve but upstream of the compressor where relatively low pressures exist, while the high-side of the system is generally downstream of the compressor but upstream of the system expansion valve where pressures are relatively much higher. Despite the high efficiency of the oil separators used in such systems, a compressor will lose a significant portion of its lubricant to the downstream components of the refrigeration system over time. Failure to return the oil to the compressor will ultimately result in compressor failure due to oil starvation. In some screw compressor-based refrigeration systems, so-called passive oil return has been used to achieve the return of oil from the system evaporator to the compressor. Passive oil return connotes the use of parameters, characteristics and conditions which are inherent in the normal course of system operation, such as the velocity of suction gas, to carry or drive oil from the system evaporator back to the system compressor without the use of "active" components, such as mechanical or electromechanical pumps, float valves, electrical contacts, eductors or the like, which must be separately or proactively energized or controlled in operation. 36 The compressor performance is affected by: the temperature lift (difference between evaporating and condensing temperatures); the properties of the refrigerant (e.g. centrifugal compressors are best suited for low evaporator pressures and refrigerants with large specific volumes at low pressure, on the other hand reciprocating compressors perform better over large pressure ranges and are better able to handle low specific volume refrigerants 37 ). the temperature of the superheated suction vapour (achieved using a suction/liquid line heat exchanger). If superheat is not usefully obtained, the efficiency will be reduced because the specific volume of the suction gas will increase, reducing the mass flow and thus reducing the refrigerating capacity of the compressor for the same power consumption. In addition, if Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 35

330 the temperature of the superheated suction vapour is too low liquid refrigerant may return to the compressor and damage it. the use of intercooler systems to pull down the temperature of the refrigerant before entering the compressor Selection As described above, the efficiency of the compression process is influenced by the thermodynamic properties of the applied refrigerant. To obtain the maximum performance of a vapour compression process, a compressor design has to be selected so offers the best perspective to match the requirements given by the application and the selected refrigerant. One of the most important characteristics of the refrigerant are the pressure ratio at a given temperature (evaporating temperature of the application). A temperature increase or a pressures decrease of a refrigerant results in an increase of the specific volume and a reduction of the volumetric efficiency of the compressor, and should be minimized. When minimising the occurring pressure drop of the suction gas, compressors of the rotating type are favourable, since there is no need to re-expand clearance volume gas in this kind of machines 38. Table 4-7 shows recommendations of compressor types for selected evaporating temperatures, cooling capacities and refrigerants. Table 4-7: Recommendation of compressors for various refrigerants and applications 38 The COP is mainly affected by the temperature lift (difference between evaporating and condensing temperatures). Figure 4-16 shows that for the same evaporating temperature, the lower the condensing temperature, the higher the COP. A decrease of +1 C in the temperature lift will involve an increase of the COP by 2 to 4 %. 38 Jürgen Süss, Bjarne Dindler Rasmussen, Arne Jakobsen. Impact of refrigerant fluid properties on the compressor selection. 36 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

331 Figure 4-16: COP for a typical compressor according to the temperature lift 39 However, each compressor technology has an optimum application range. The most efficient compressor for a specific application depends on parameters that are specific to that application (such as cooling capacity), and therefore this should be taken into account when assessing compressor technologies. Table 4-8 below shows the average compressor type used for different cooling capacities, according to information provided by stakeholders. The drivers in this decision are mostly production, installation and running costs. Table 4-8: Compressor types used by cooling capacity ranges 0kW-20kW 20kW-50kW >50kW Reciprocating hermetic Reciprocating semi-hermetic Reciprocating semi-hermetic Reciprocating hermetic Scroll Scroll Screw Screw In general, the first technology for compressor application is reciprocating with an average COP of 2.5. Following this, scroll and screw compressors were introduced to achieve higher efficiency levels for refrigeration compressors since they use less power to rotate than pistons and cranks. For example, the scroll compressor can achieve up to 30% of efficiency improvement compared to reciprocating technology, if it is used at the workload and ambient conditions it was designed for. Scroll and screw compressors in principle offer more reliability than reciprocating compressors, if the oil system is designed and maintained properly, but under deviation on the working conditions, the energy performance of these types of compressors decreases more severely compared to reciprocating types. The market prices are around 25% higher for equivalent sizes of scroll type compressors compared to reciprocating type. The latest development centrifugal compressor is generally more efficient than rotary vane screw and scroll types UK Energy Efficiency Best Practice Program. Energy efficient refrigeration technology the fundamentals, Good Practice Guide n 280. Available at: 40 Mark Ellis & Associates, In from the cold Strategies to increase the energy efficiency of nondomestic refrigeration in Australia & New Zealand, 2009 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 37

332 Control Moreover, the improved gas management as well as optimised motor matching to the specific compressor displacement and its application might improve the COP within existing technologies. In medium temperature applications (i.e. between i.e. between 0 C and +4 C) 41, the COP of a scroll compressor is assumed to be higher than for a reciprocating compressor at operating conditions, assuming an annual average condensing temperature between +20 C and +30 C, which is representative of today s applications. For low temperature applications, standard scroll compressors show lower COPs. Therefore, the choice of the compressor depends mostly on average annual evaporator and condenser temperatures. A compressor is chosen to supply enough power even during high cooling loads. However, most of the time, it does not operate at 100%. Therefore the compressor with the best COP under nominal conditions (with maximal cooling load) is not necessarily the best under real operation conditions. The ideal choice of the compressor should depend mostly on average annual evaporator and condenser temperatures. Traditional compressor motors run multiple start-stop cycles in order to maintain the desired temperature. Compressor control can enable adaptation of the cooling capacity to changing operating conditions. Several control devices are available to optimise compressor operation to the cooling power required: On/off control: these controllers are applicable to a wide range of compressors and are the most common control type. They are simple in action and not very expensive. They activate or de-activate the equipment through readings taken from a probe (e.g. pressure drop). This technology seems to be the most common in the market. Cylinders control: in reciprocating compressors, the suction vapour is stopped from entering one or more cylinders, thus reducing the pumping rate of the compressor. This technology does not seem to be of general use in the market. Step control: used when several compressors are installed in parallel, one or more of the compressors can be deactivated to effectively achieve a partial load operation of the system. This is more effective than having one larger compressor working at low capacity. This technology, due to the high cost of having a second compressor, is only applied in condensing units of medium and high capacity, over 20kW-30kW. Continuous compressor capacity control: generally achieved through variable speed or similar technologies. The speed of the motor is adapted according to the cooling power required. Digital modulation control: a continuous capacity modulation technique specifically developed for scroll compressors. Digital modulation not only controls the speed of the compressor motor, but also the flux of the 41 Source: Thermal evaluation of low and medium temperature refrigerated facilities. Phillip C. McMullan; TSI Thermo Scan Inspections; Indiana USA 38 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

333 refrigerant and other components of the condensing unit such as the expansion valve. This technology is claimed to achieve higher energy savings than variable speed motors in conditions of variable workload. However, if the system works at full load, most of the time the digital variable speed technology is not beneficial. Without taking into account the price, the choice of the control depends on the type of compressor, and real-life operational conditions. The common industry practice for larger remote refrigeration systems is to oversize design capacity in order to add a safety margin due to the potential risk issues resulting from insufficient capacity (e.g. during times of high ambient temperature for a given climate). Therefore, compressors in large refrigeration systems often work at part-load. It is estimated that compressors in refrigeration systems work at an average capacity of 70%-80% of the full load, with seasonal peak variations of 30%-40%. Within this scenario, a VSD compressor is more efficient, hence the most efficient architecture should be analysed and chosen regarding the overall performance of the system. For compressors, VSD adaptation to load can reduce the refrigerant flow rate and consequently to operate at lower pressure ratio than at full capacity, improving the efficiency as compared to full capacity. A motor that modulates the compressor speed rather than switching on/off, adjusting it to the workload, also increases the reliability and durability of the compressor. At full load, a VSD compressor is not as efficient as a comparable constant speed compressor because the variable-frequency drive increases power draw by 2% to 4%. In addition, for variable speed compressors integrating DC inverter systems, the efficiency of the compressor decreases because of the efficiency loss induced by the inverter, around 3 to 5%. As 100% power is approached, the constant-speed compressor is more efficient than the VSD compressor. Therefore VSD compressors only allow energy savings when working under part load conditions. Generally, if a constant-speed compressor is expected to operate above 80% of its capacity, it is the more efficient choice. On the other hand, if the constant-speed compressor operates below 80% of its capacity, then replacing it with a VSD compressor will provide additional savings. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 39

334 Figure 4-17: The annual savings percentage available by installing a 93 kw VSD compressor versus a 93 kw constant speed compressor 42 Therefore, when the workload and air-on temperature are mostly constant during the year, variable speed controls do not achieve energy savings compared with onoff controls. VSD compressors are well suited as trim compressors, working in parallel with 1 base load compressor. The base-load compressor operates at a constant-speed, at its maximum efficiency as required, while the trim VSD compressor would cycle on and off in order to match fluctuating system demand. However, these savings are only achievable in large capacity units, when the compressor rarely works at full capacity EXPANSION DEVICE The expansion valve is a device used to control the refrigerant flow rate to match the amount of refrigerant being boiled off in the evaporator, adapt the cooling capacity to meet demand, and regulate the superheating of the refrigerant. The valve provides the flow resistance necessary to maintain a pressure drop in the system, separating the high pressure side (P2 in Figure 4-2) from the low pressure side (P1 in Figure 4-2). Expansion devices used in refrigeration appliances are: capillary tubes (typically found in smaller refrigerating and freezing equipment) and orifice plates; thermostatic expansion valves (with balanced port for bi-flow applications); and electronic expansion valves (e.g. modulating or stepper technology). 42 Chris E.Beals, Unwinding the Spin on Variable Speed Drive Air Compressors, Proceedings of the Twenty-Eighth Industrial Energy Technology Conference, New Orleans, LA, May 9-12, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

335 Capillary tube The capillary tube is small diameter tubing that offers the restricted flow of the refrigerant. The pressure drop attained through the capillary depends upon its diameter and length. Capillary tubing is used for small refrigerating and airconditioning systems. Overcharging can lead excessive high discharge pressures from the compressor, which leads to over loading of the compressor and the chances of refrigerant leakages from the system are also increased 43. Capillary tubing is usually made of copper Thermostatic expansion valve A typical thermostatic expansion valve (TEV) comprises a valve body, a stem connected to a spring and to a metal membrane, and a sensing system consisting of a bulb and a capillary tube which is partially filled with some refrigerant. The inside of the valve is in open contact with the evaporator but separated from the sensing system by the membrane. The bulb is placed in contact with the end of the evaporator. Above the membrane, the pressure corresponds to the evaporation temperature of the refrigerant in the bulb (bulb pressure) which itself corresponds to the temperature of the superheated refrigerant vapour. A TEV is chosen according to the system s pressure drop and design evaporator cooling capacity adjusted with the subcooling to ensure the desired evaporating temperature and superheat is reached for a set condensing temperature. This type of valve is set to maintain approximately the same superheat at the end of the evaporator at all conditions. The mass flow of refrigerant through the evaporator will vary in response to the changes in the heat load sensed by the bulb. If the compressor is stopped, no superheat is sensed and the valve is closed. A basic thermostatic expansion valve operates depending on three forces, demonstrated in Figure These are: the closing force P b ; the spring pressure P s ; and the evaporator pressure P 1. When the evaporator pressure increases while P b remains the same, the valve closes. If the bulb pressure increases to the larger amount, the valve opens (P b > P 1 +P s ) 43 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 41

336 Electronic expansion valve Figure 4-18: Example of a TEV 44 Using an electronic expansion valve (EEV), it is possible to decrease the superheating of the evaporator, improving the refrigeration product s performance, as compared to the TEV. Moreover, it allows a better control of the temperature, which insures a better preservation of products under variable ambient conditions. 44 Source: HVAC Mechanic Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

337 EVAPORATOR Evaporation of the refrigerant occurs in the evaporator (i.e. heat exchanger). The vaporisation is maintained through the suction effect of the compressor on the refrigerant, keeping a low pressure in the evaporator. When the refrigerant evaporates, it removes heat from the surroundings of the evaporator. Typically, in refrigeration equipment, evaporators are immersed in the medium being cooled and close to the product being cooled. +27 \\ Types Figure 4-19: Illustration of common evaporator used for refrigeration Before being transferred to the compressor, the vapour refrigerant can be heated over its evaporating temperature through use of a liquid suction heat exchanger (i.e. superheated by heat exchange with the liquid exiting the condenser) to prevent the transfer of liquid droplets in the compressor, which would impair its operation (see ). Air type evaporators are the most typically used in commercial refrigeration equipment. The difference is that the air evaporator wholly vaporizes the refrigerant before it reaches the suction line in the compressor. Flooded evaporators can be used in process chillers. In the case of flooded evaporators, to avoid liquid refrigerant getting into the compressor and damaging it, a receiver is added at the outlet of the evaporator. The vapour and liquid phases are separated; the vapour circulates through the compressor, and the liquid is reinserted into the Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 43

338 evaporator. Thus, flooded evaporators are also called recirculation-type evaporators. This type of evaporator has a heat transfer coefficient higher than an air evaporator, and is therefore more efficient. However, flooded evaporators are more expensive to operate (they require twice more refrigerant charge and create added cost for liquid/vapour separator as well as oil recovery method required), and ensuring that oil returns to the compressor is important to maintain its performance. Moreover, flooded evaporators are mainly used for large capacity applications due to their greater efficiency. One advantage of flooded evaporator coil is increased heat transfer capacity because areas of reduced heat transfer are smaller (boiling of refrigerant occurs over a greater area of the evaporator) Characteristics The evaporating temperature is one of the operation conditions of the refrigeration equipment which is determined according to the refrigerating effect needed. A high evaporating temperature is desirable. The density of the refrigerant suction vapour entering the compressor is a function of the evaporating pressure P1 (see Figure 4-2). The higher the vaporising pressure, the greater the density of the suction vapour. For a given volume of vapour handled by the compressor, a greater mass of refrigerant is drawn when the suction pressure is high (when the suction temperature is high). Q2 (see Figure 4-1) increases and the performance is improved. The ARI standard provides COP values for a typical reciprocating compressor used for remote refrigerated equipment. It is clearly visible, as shown in Figure 4-20, that the higher the Adjusted Dew Point 45, the higher the COP. The adjusted dew point temperature is defined in ANSI/AHRI as being lower than the actual Dew Point temperature (refrigerant vapour saturation temperature at a specified pressure) resulting from suction line pressure losses, equal to saturated suction temperature at the compressor. 45 Dew point can relate to both evaporating temperature (suction dew point) and condensing temperature (discharge dew point) the Dew Point temperatures differ due to the different pressures at evaporation and condensation. 44 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

339 COP COP variation function of Adjusted Dew Point Temperature Medium Temperature Low Temperature Adjusted Dew Point Temperature ( C) Performance Figure 4-20: Influence of the evaporation temperature on the efficiency of the refrigeration cycle 46 Q1 (i.e. the amount of heat transferred from within the refrigeration equipment to the refrigerant circulating in the evaporators) is also a function of the heat transfer properties at the evaporator. The heat transfer of an evaporator is related to the evaporator s heat exchange surface area and heat transfer coefficient. The heat transfer coefficient is a function of the difference between the evaporating temperature of the refrigerant and the temperature of the evaporator s surroundings, the surface area of the evaporator s heat exchanger, the flow of refrigerant through the evaporator and the flow of air around the evaporator. Fans are often used in order to increase the heat transfer (e.g. increase the flux and therefore the heat transfer coefficient). Evaporator fan motors in refrigeration systems commonly operate at constant speed; however, increasingly, manufacturers suggest the use of variable speed fan motors (i.e. two-speed fans) to allow reduced energy consumption when less refrigeration load is required. A larger surface area increases a heat exchanger s heat transfer capacity; however, the flow of refrigerant through a larger evaporator must then be properly controlled to ensure its full use. Heat exchangers, used in both condenser and evaporator components, have undergone new developments in the field of microchannel heat exchangers. These developments provide an opportunity to increase the active heat exchange surface area of air cooled heat exchangers, leading to a potential reduction of the dimensional footprint of the component (maintaining 46 Source: ARI standard. The COP values presented in the figure are based on an evaporator temperature and the Commercial Refrigerated Display Merchandiser or Storage Cabinet classification. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 45

340 the same heat exchange capacity with smaller heat exchanger) or increased heat exchange capacity, using the same sized component. In addition, importantly, it also can reduce the refrigerant charge. This will be discussed further in Task 5 as a Best Available Technology CONDENSER Types The condenser s function is to reject heat from the refrigeration-cycle to the ambient surroundings. The refrigerant vapour enters the condenser (i.e. heat exchanger) where it is cooled down by transferring its heat to a coolant fluid. This coolant fluid might be air, water, or a combination of both. Fins, wires, or plates may be fastened to condenser tubing to increase the surface area and the ability to dispose of the heat of condensation. Fans or pumps are commonly used to increase the flow of the condensing medium. Such enhancements increase the sub-cooling of the refrigerant, increase the rate of heat transfer, and decrease the overall size of the condenser. The types of condensers used in refrigeration appliances 47 are: air cooled (using ambient air); water cooled using either groundwater, cooling tower, river, or mains water (although this should be discouraged to consumption of mains water); and evaporative-cooled (using ambient air and re-circulated water). All three types of condensers mentioned above have specific energy needs because of the components used, including: fan power for air-cooled condensers; circulating pump power (and in some cases cooling tower components) for water-cooled condensers; and both fan and pump power for evaporative condensers. A typical air cooled condenser uses propeller type fans to draw the surrounding air over a finned-tube heat transfer surface (a large surface is required to compensate the relatively poor heat transfer characteristics of air) and increase the heat transfer coefficient. This is the major cause of noise problems connected to the air-cooled condenser use. 47 Source: Energy Efficiency Best Practice Programme UK (2000). Energy efficient refrigeration technology the fundamentals. Good Practice Guide Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

341 Table 4-9: Illustration of Common type of condensers Characteristics As in the case of evaporators, the amount of heat transferred at the condenser, and therefore the energy consumption of the overall refrigeration system, depends on: the temperature difference between the inside and the outside of the condenser (i.e. between the refrigerant and the cooling medium); the size of the condenser (a larger surface area will enable an increased amount of heat to be transferred); and the flow of the fluids in contact of the condenser. Therefore, the condensing temperature of the refrigerant has an impact on the system s efficiency and should be kept as low as possible to ensure low energy consumption. When T2 (see Figure 4-2) increases, Q1 (see Figure 4-1) decreases. Typically, a +1 C increase in condensing temperature can lead to a 2 to 4% increase in energy use by the refrigeration system. Thus, keeping the condenser temperature difference as small as possible, it is ensured that the system condensing temperature is as low as possible, which leads to the lowest energy consumption and best COP for given ambient and load conditions. The purpose of condenser capacity control is to maintain system condensing temperatures artificially high to ensure a sufficient pressure differential is available to enable flow through expansion valves. All other factors being equal, increasing the condensing temperature increases the compression ratio and reduces the 48 Source: Energy Efficiency Best Practice Programme UK. Energy efficient refrigeration technology the fundamentals. Good Practice Guide Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 47

342 Performance volumetric efficiency and the isentropic efficiency of the compressor. As a result, the total efficiency of the compressor decreases. Since the saved fan power is almost always outweighed by increased compressor power consumption, the technique is inherently inefficient and should be avoided where possible. In condensers with condensation inside the tubes and no receiver, the amount of refrigerant can be controlled so that the last section of the heat exchanger acts as a subcooler. In air cooled condensers, the subcooling section is placed on the air inlet side. To ensure effective operation of the condenser, good maintenance practice is required (i.e. regular cleaning) to prevent debris from blocking the airflow and hence limiting the heat transfer. As for evaporator fans, condenser fans can be controlled to reduce their energy consumption. Most condenser fans use constant speed motors, however, variable speed motors or two-speed fans, allowing reduced electricity consumption when less refrigeration load is required, can also be used. However, reduced fan speed and hence air flow over the condenser needs to be considered in light of the fact that larger air flows will help keep head pressure (compressor exit pressure) down, reduce power consumption, and contribute to a long service life of the compressor. For on/off systems, some of the condenser fans might be switched off at lower load, and if so, some of the condenser coil will not be being ventilated, hence some efficiency will be wasted. Variable speed fans do not need to stop when the flow is reduced (if there are several, they can each be slowed), hence the whole surface of the heat exchanger will have air blown over it. However, as discussed in , this technique of condenser control is considered to be inadvisable as it is unlikely to reduce overall energy consumption. Water has better heat transfer properties than air; therefore, water-cooled and evaporative-cooled condensers are typically more efficient than the air-cooled ones. In the case of water-cooled and evaporative condensers, pumps can be used to improve the heat transfer, and in this case the power input of the machine will increase. Evaporative condensers have even better efficiency than water-cooled ones, since they reduce the water pumping need. They also result in a lower heat sink temperature, which allows a lower head pressure or a smaller condenser. Choosing an evaporative condenser instead of commonly used air cooled condensers can lead to 8.2% reduction in electricity consumption 49. However, compared to conventional condensers, these products have a higher capital cost (from 40 /kw cooling capacity to 80 /kw cooling capacity for air-conditioning equipment 50 ), and require more maintenance and water consumption. In addition, their use has been cautioned in relation to the potential growth of Legionella bacteria and subsequent health concerns 51. They are therefore rarely used in certain countries (e.g. the UK). 49 Walker D.H., Van D.B. Analysis of Advanced, Low-Charge Refrigeration Systems for Supermarkets. Oak Ridge National Laboratory. 50 Davis Energy Group (1998). Evaluation of residential evaporative condensers in PG&E service territory. California USA 51 Source: 48 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

343 Because of the lack of space, plug-in refrigerated appliances use an air cooled condenser. In the case of remote products, water cooled or evaporative condensers are commonly used. Good ventilation, as discussed above, will help keep head pressure (compressor exit pressure) down, reduce power consumption, and contribute to a long service life for the compressor. Further, a simple way to reduce the condensing temperature of the refrigeration system is to use an electronic expansion valve, which allows reduction of condensing temperature. Developments in heat exchanger technology, as discussed above in the evaporator section, could either decrease the dimensional footprint of condensers, while maintaining similar heat exchange capacity, or increase the energy efficiency of a condenser with a heat exchanger of equal size, through increased active heat exchange PUMPS Pumps are sometimes used within process chiller systems, and as discussed in Task 1 are being currently considered for regulation under Directive 2009/125/EC. Please see Task 1 for more details. Electric pumps covered are single stage end suction, vertical multistage and submersible multistage pumps. In commercial and industry refrigeration sector, especially in chillers, single stage end suction and vertical multistage pumps might be used. Three categories of single stage end suction water pumps are included: end suction own bearing (ESOB); end suction close coupled (ESCC); end suction close coupled in-line (ESCCi). For smaller installations, circulators could also be used. Following is the specification according to working document of these two types of pumps: Table 4-10: Water pumps used in the refrigeration sector considered for regulation under the Eco-design directive in the future 52 Single stage end suction water pumps Operating temperature between -10 and +120 C Single suction, single impeller All efficiencies based on full (untrimmed) impeller Some further explanations on these terms are: Vertical multistage (MS) water pumps Operating temperature between -10 and +120 C Vertical multistage pumps in in-line and ring section design Efficiency is measured and judged on the basis of a 3 stage pump Stage: the quantity of impellers within the equipment to develop the head (pressure). When they are more than one (multistage), they work in series. 52 Working document on possible eco-design requirements for single stage end suction, vertical multistage and submersible multistage pumps Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 49

344 Impeller: the rotor inside the equipment which increases the pressure of the fluid. Efficiency: ratio of the power imparted on the fluid (by the pump) and the power supplied to drive the equipment. Table 4-11: Total annual energy consumption for different types of pumps 53 Pump type Total annual energy consumption (kwh pa) End suction close coupled (s) 7,291 End suction close coupled (l) 32,610 End suction in line close coupled (s) 10,906 End suction in line closed coupled (l) 53,325 End suction own bearings pump (s) 8,631 End suction own bearings pump (l) 32,588 Submersible multistage (s) 2,141 Submersible multistage (l) 4,956 Multistage pump (s) 3,074 Multistage pump (big) 1,356 (S): small (l): large The potential improvements for pumps were presented in TREN Lot 11. Below is a summarising list of the possible improvements for these equipments: end suction own bearings pumps: hydraulic design: improving the geometry by replacing cast impellers; surface friction of the impeller: eliminating surface roughness by using coats of smooth resins; surface friction of the casing (same case as for the impeller); leakage: increasing shaft diameter, using harder materials for wear rings, using a large conical housing for the seal to avoid the bleeding of water, among others. end suction close coupled pumps: hydraulic design: improving the geometry by replacing cast impellers; surface friction of the impeller: eliminating surface roughness by using coats of smooth resins; surface friction of the casing: same case as for the impeller; leakage: using harder materials for wear rings, using a large conical housing for the seal to avoid the bleeding of water, among others. 53 Source: BIO Intelligence Service. Appendix 6 : Lot11 Water pumps (in commercial buildings, drinking water pumping, food industry, agriculture) Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

345 vertical multistage pumps: hydraulic design: increasing the number of stage and its width can increase the efficiency; leakage: using harder materials for wear rings. positive displacement pumps (rotary, reciprocating, and open): no improvements identified. using intelligent controls in centrifugal pumps. using optimal specific speed motors, thanks to the implementation of electronic controls. Variable Speed Drivers pumps can provide up to 50% of energy savings by adjusting the flow to meet actual system requirements. The percentage of equipments currently sold with this characteristic is as follows: end suction own bearing: 4%; end suction close coupled: 5%; end suction close coupled in line: 30%; multistage water: 8%; and multistage submergible: 1%. In process chiller systems, depending of the complexity of the cooled water circuit, a single circuit (primary circuit) for the chiller and a secondary circuit for the customer are used. Due to poor installation, the actual performance of the water pumping system might be as much as 28 to 56% lower than the performance claimed by the manufacturer LIQUID SUCTION HEAT EXCHANGER Liquid suction heat exchangers are commonly used in refrigeration systems to ensure the right operation of the system and increase its performance. Figure 4-21 shows the refrigeration cycle including a liquid suction heat exchanger, which allows exchange of energy between the cool gaseous refrigerant leaving the evaporator and warm liquid refrigerant exiting the condenser. 54 M. Merchat, Mesure des performances énérgétique des systémes de refroidissement, 2009 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 51

346 Figure 4-21: Schematic representation of refrigeration cycle with a liquid suction heat exchanger ASHRAE 55 states that liquid suction heat exchangers are effective in: increasing the system performance; subcooling liquid refrigerant to prevent flash gas formation at inlets to expansion devices; and fully evaporating any residual liquid that may remain in the liquid-suction prior to reaching the compressor (which might damage it). Liquid has been known to destroy compressors by snapping connecting rods and crankshafts. It is stated that liquid slugging is the direct cause of 20% of the mechanical failures in the compressor 56. In addition, reciprocating compressors (more than other types of compressors) have been shown to be particularly vulnerable to liquid slugging 57. However, liquid-suction heat exchangers could increase the temperature and volume of the refrigerant entering the compressor, causing a decrease in the refrigerant density and compressor volumetric efficiency. 55 ASHRAE: American Society of Heating, Refrigerating and Air-Conditioning Engineers 56 Stouppe, D. and Lau, T. Air conditioning and refrigeration equipment failures. National Engineer, 93:14 17 (1989). 57 Liu, Z. and Soedel, W. A mathematical model for simulating liquid and vapor two-phase compression processes and investigating slugging problems in compressors. HVAC+R Research Journal, 1(2): (1995). 52 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

347 Figure 4-22: Pressure- Enthalpy diagram showing effect of an liquid-suction heat exchange 58 When a liquid-suction heat exchanger is employed, the refrigerant entering the compressor (state 2) has been superheated by heat exchange with the liquid exiting the condenser which causes the liquid to enter the expansion device in a subcooled state (state 4). However, pressure drop issues always occur in the heat exchangers. The choice of installing a liquid suction heat exchanger is a compromise, and depends on the temperature lift (difference between condensing and evaporating temperatures) of the system and the refrigerant used. As can be seen in the figure below, it is detrimental to system performance in systems using R717 (ammonia) as refrigerant since they are characterised as very high temperature substances. Figure 4-23: Relative capacity (and relative system COP) index as a function of liquid-suction heat exchanger effectiveness for various refrigerants at -20 C evaporating temperature and +40 C condensing temperature S. A. Klein, D. T. Reindl, and K. Brownell, Refrigeration System Performance using Liquid-Suction Heat Exchanger, 2000 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 53

348 LIQUID RECEIVER For proper operation of the expansion valve, all the refrigerant on the high pressure side must be in liquid phase. To ensure this, the refrigerant should, if possible, be subcooled a few degrees at the exit of the condenser. If the refrigerant is not subcooled, pressure drops in the tubes, and height differences between the condenser and the expansion valve, may cause formation of vapour bubbles. A liquid receiver is therefore placed between the condenser and the expansion valve. During operation, the receiver is partially filled with refrigerant liquid and as the outlet is placed in the bottom, only the liquid phase can leave the receiver. A liquid receiver is used in all refrigeration systems except in those using a capillary tube expansion device technology (capillary tube expansion devices can be found in smaller refrigerating and freezing equipment such as plug-in service cabinets, dessert and beverage machines, ice-makers) and the main functions of this component are to: hold a reserve of refrigerant to ensure there is always refrigerant available with a change in the evaporator load; and in some cases, hold the whole refrigerant charge during pump-down operation (purge). The liquid receiver gives stability to the overall efficiency of the refrigeration system. Subcooling occurring in the condenser is lost when the liquid enters the receiver and flashes to the saturated state, lowering the pressure slightly. It needs to be further subcooled downstream of the receiver to prevent vapour bubbles being present at the TEV. Some types of condensers also operate as receivers PIPING SYSTEM Copper or steel pipes are used to link the different components. The piping system is designed and installed to: minimise pressure drops and ensure the difference between the condensing and evaporating pressures is as low as possible to maintain efficiency; avoid refrigerant leakages; and allow oil return to the compressor by maintaining high velocity for the refrigerant (in the case of vapour-compression cycles), as discussed in Insulation is required on the suction line INSULATED ENCLOSURE Insulation reduces heat transmission (hence reduces heat load) from the ambient environment, through the equipment enclosure, into the refrigerated storage 59 S. A. Klein, D. T. Reindl, and K. Brownell, Refrigeration System Performance using Liquid-Suction Heat Exchanger, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

349 space. Wall losses 60 can be reduced by improved insulation, leading to reduced head load which in turn requires a refrigeration system with smaller cooling capacity, and hence can lead to reduced energy consumption of the equipment. There are various materials used as insulation, but predominantly in refrigeration equipment this is polyurethane (PUR) or polyisocyanurate (PIR) foam. A blowing agent is used to foam these materials to create a cell. Both the material used for insulation and the blowing agent should therefore have low thermal conductivity. Refrigerants, when used for blowing agents, can increase the direct emissions of refrigeration equipment as the gas permeates out of the foam structure, as the insulation degrades during life. The environmental impacts of HFCs are encouraging refrigeration equipment manufacturers to identify other, more ecofriendly blowing agents. In EU production, use of HFC as blowing agent involves less than 10% 61 of the insulation produced. Besides HFCs, cyclopentane, isopentane, CO 2, water and HFOs have also been used; however, the thermal conductivity of such blowing agents is higher than that of HFCs. Therefore, this does not lead to a reduction of energy consumption but will help in reducing environmental impacts such as Global Warming Potential (GWP). Manufacturers can use a higher insulation thickness to compensate for the energy loss. Various insulating materials and ranges of thermal conductivities (and ranges of thicknesses required to provide U value of between 0.1 and 0.2 W/m 2.K) are presented in the figure below. found. Error! Reference source not 60 Wall looses refers to heat gain from surroundings of service cabinets 61 Source: ISOPA Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 55

350 Figure 4-24: Insulation properties ANTI-CONDENSATION HEATER Anti-condensation heaters can be used in refrigeration appliances with doors to heat the area around the door seal of the appliance to prevent condensation, and consists of an electrical resistance coil heater or other system of heating such as hot refrigerant gas from the compressor. For example, service cabinets can include an anti-condensation heater to prevent moisture from forming on the outside of the refrigerator during hot, humid weather. Moisture could lead to ice build-up on door gaskets, sweating where temperatures at the product skin fall below dew point, and to fogging in the case of glass doors or windows DEFROSTING Service cabinets, blast cabinets and walk-in cold rooms are mostly used in catering facilities (e.g. kitchens, bakeries) where ambient humidity is high (around 60 %). When in contact with the evaporator, the moisture condenses and freezes. A layer of frost forms on the outside of the evaporator, acting as an insulator and hindering the heat exchange with the air (that needs to be cooled). This results in poor energy efficiency. Regular defrost prevents ice build-up. Different types of defrost methods exist: defrost through compressor shutdown, electric defrost and hot or cool gas defrost Compressor shutdown Electric In the case of defrost through compressor shutdown, the flow of refrigerant liquid in circulation inside the evaporator is temporarily stopped but the ventilators are kept in operation. The evaporator heats up, melting the ice, and the water resulting from defrost is drained and collected in the defrost water tray. The water from defrosting is then either evaporated within the appliance s storage volume (using an evaporator pan) or drained externally (drain line). Defrost cycles are set automatically 63 and stop when the evaporator surface temperature rises to above 0 C, at which point no frost remains. The evaporator is then fed with refrigerant liquid and the vapour compression cycle can restart. However, this defrost method is only acceptable for chilled refrigerated equipment, and cannot be operated in the case of freezers because it would increase the refrigerated space temperature to above that required for food preservation. 62 Source: Birch, A., Vacuum insulation panels promise a thinner future, 08/05/ The defrost operation can be automatic (no end-user action is required to initiate and stop the defrost), semi-automatic (automatic defrost with manual removal of the defrost water, or defrost initiated by the end-user which then stops automatically), or manual (the defrost is initiated and stopped by the end-user). 56 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

351 One common defrost method used to reduce the duration of the ice melting is the electric defrost, through the use of heating filaments. They consist of heaters that are fixed near the evaporator (defrost coil which is integrated to the evaporator coil) and that are switched on to accelerate defrost. During this process the refrigerant supply is switched off and the ventilators are kept in operation to blow warmed air on to the evaporator. A few minutes are then needed to achieve the complete melting of the ice. However, higher electricity consumption is needed for the resistances and defrosting brings heat to the refrigerated storage space that needs to be taken out Hot or cool gas Hot or cool gas defrost are potentially efficient methods, although they require additional piping (implying higher risks of refrigerant leakages) and maintenance. Hot gas defrost uses the hot discharge (high pressure) gas directly from the compressor piped to the evaporator. Cool gas defrost involves the circulation of gas from the liquid receiver with a control valve to begin and end the defrost cycle. The cool or hot gas condenses in the evaporator, releasing heat which melts the ice from the evaporator coils. The merits claimed for cool gas defrost are that there is less temperature shock to the piping and evaporators compared to hot gas defrost. During this operation, the fans are switched off to prevent water carry-over from the coils. The refrigerant leaving the evaporator is piped back to the liquid manifold of the compressor pack for distribution to other refrigeration equipment connected to the system CONTROL SYSTEMS Control systems can be used to manage refrigeration systems, and these control systems have been developed to adapt certain physical parameters of a refrigeration system in order to maximise energy efficiency. For example, control systems can increase system efficiency through algorithms that regulate the activation of compressor(s), variation of fan speed, and an electronic valve function, as described in the component sections above, hence reducing the system s energy consumption. Particularly when the efficiency of the best available component is high, the application of an intelligent control algorithm can enable greater energy savings, for example self-adaptive evaporating and condensing temperature, self-adapting defrost control, or connection to a building management system, with pro-active alarm management to provide warning of malfunctions or breakdowns. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 57

352 4.7. PRODUCT TECHNICAL ANALYSIS This section describes the functionality of the products, their components, the factors affecting their energy consumption and average technical parameters. The table below describes the components typically included in each of the five product groups. Table 4-12: Components included in product groups Service cabinet Blast cabinet Walk-in cold room Process chiller Remote condensing unit Compressor Y Y Y Y Y Condenser coil Y Y Y Y Y Condenser fan Y Y Y Y Y Evaporator coil Y Y Y Y N Evaporator fan Y Y Y Y N Insulation Y Y Y Sometimes on piping and in housing Sometimes in housing if outdoors Anti-condensation Sometimes N Sometimes N N Defrost Y Y* Y N N Door Y Y Y N N Lighting Sometimes N Y N N Glass Sometimes N Sometimes N N Other Y: included in product N: not included in product *Only equipment including freezing mode 58 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

353 SERVICE CABINETS Product description at component level Preliminary analysis shows the typical service cabinet will be a single-door, vertical plug-in model, of net internal volume around 450 litres, providing a storage temperature range of around +2 C for refrigeration or -18 C for freezing. Figure 4-25 provides the technical drawing for a 2-door plug-in vertical service cabinet. Figure 4-25: Service cabinet and major components The refrigeration system is usually located at the top of the unit to keep the refrigeration components away from spills and dust and to allow easy access for maintenance. The evaporator is located inside the cabinet housing, at the top. Compressor The compressor used within average service cabinet is a hermetic reciprocating one with the capacity of 351W and power of 320W. The weight of the compressor is usually between 10 to 14 kg. In plug-in freezing appliances, the compressor s electricity consumption may represent around 70% of the overall energy consumption and 60% for refrigeration remote appliances 64. An increase of the compressor efficiency (e.g. by reducing suction and discharge gas pressure losses, mechanical losses (frictions), and electrical losses (motor) can reduce the total electricity consumption of a cabinet by around 12% 64. Advanced control technologies to enable variable speed drive 64 can reduce the total electricity consumption of service cabinets by 10 to 15%. At the moment, 64 Source: Arthur D. Little Inc, Energy Savings Potential for Commercial Refrigeration Equipment, US DOE, 1996 and MARK ELLIS & Associates, Self-Contained Commercial Refrigeration, Australian Greenhouse Office, 2000 and MARK ELLIS & Associates, Remote Commercial Refrigeration, Australian Greenhouse Office, 2000 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 59

354 such control devices are typically not present in plug-in service cabinets, but can be found in the compressors of refrigeration systems for remote service cabinets. However, as explained before, this energy saving varies depending on the workload and ambient conditions. It has to be noted that the above-mentioned figures are referenced as for year 1996 and the updating feedback from the stakeholders indicate that potential improvement for compressor can only be 5% by Expansion device The average expansion valve type is a capillary tube, while remote condensing will use a thermostatic expansion valve (remote service cabinets are considered to be rarely purchased). The thermostatic expansion valve can have an impact on the remote cabinet s energy efficiency by allowing the control of the flow of refrigerant into the evaporator in order to vary system capacity to meet demand (enabled savings around 5 to 10% 65 ). Evaporator Typical service cabinets include one or several evaporator fans to ensure air circulation and an even temperature distribution. Evaporator used in the average service cabinet uses 1 fan with the 200mm diameter and the blade at the 28 angle. The face area of the evaporator is 240cm 2 and the air flow is around 240m 3 per hour. The fan motor type is the axial sucking and the fan wattage is equal to 5W. The total weight of the evaporating module is 1 kg. The motors driving the fans can represent between 5 and 10% of the total electricity consumption, at design conditions, of service cabinets for freezer and refrigerators respectively 64. For service cabinets, potential improvement of the evaporator fan motor could lead to 2 to 5% of total electricity savings. Condenser Plug-in refrigerated service cabinets commonly use air-cooled condensers located at the top or bottom of the cabinet. The average air-cooled condenser module consists of 1 fan with the 254mm diameter and the blade at the 22 angle. The face area of the condenser is 730cm 2 and the air flow is around 600m 3 per hour. The fan motor type is the axial sucking and the fan wattage is equal to 10W. The total weight of the condensing module is 1.5 kg. Remote service cabinets might use either water-cooled or evaporative condensers, although remote condensation for service cabinets is very rarely used. Typically, condenser fans represent about 10% of the service cabinet s total energy consumption. Variable speed or two-speed fan motors can provide energy savings of around 3% 64. However, if these variable speed fan motors prevent the condensing temperature from falling, this could reduce the system efficiency and increase the energy consumption. In the majority of cases controlling condenser fan speed results in a net loss of COP. However, there is an optimum condensing 65 Source: BIO intelligence Service, Ecodesign Preparatory Study Lot 12 on commercial refrigerating equipment, DG TREN, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

355 temperature for supermarket packs (about +21 C) when the condenser capacity is achieved through high power fans rather than surface area 66. Controls The average service cabinet does not necessarily have an anti-condenser heater, but is equipped with a defrost system. The electric defrost has a direct energy consumption that can represent around 6% of the overall energy consumption of freezing appliances 64. Defrost drip trays are used to drain away or re-evaporate water resulting from defrosting 67. Energy savings between 14 and 20% 68 can be achieved through a control device which enables to avoid the continuous operation of anti-condensation heaters (either timer or humidity sensor-based controls). Refrigerant The standard choice of refrigerant for service cabinets is R-134a. The usual amount employed of this refrigerant varies from 220 to 400g 69, but can be greater 70. However, HCs such as R290 and R600a are already being used in equipment 71. Stakeholder comments suggested that the use of some HCs as refrigerants can save up to 5% more energy than the use of other refrigerants. Housing and insulation The door is made of stainless steel and the housing is insulated using 60 mm thick polyurethane (PUR) panels 72, with the blowing agent commonly being HFC or HC 73. Different door configurations are available on the market; these configurations range from the number of doors to the position of the door itself. The gasket seals the contact area between door and the inside of the service cabinet and contributes to its proper insulation. Increase of insulation thickness can lead to around 2% reduction of total service cabinet electricity consumption 74 however, either internal space will decrease or external dimension will increase. Therefore, a balance between these factors is necessary in order to reduce overall energy consumption and maintain the service cabinet desired dimensions. In a small number of models (estimated at 1 to 2% 75 ), a transparent door may be used in place of a solid door. The U value of a foamed (solid) door might for example be W/m 2.K, while for a glass door this may be 1.1 W/m 2.K or more. 66 Source: Defra 67 Source: Friginox, Gram 68 Source: APS Utility service 69 Source: UNEP. Report of the Refirgeration, Air Conditioning and Heat Pumps Techinical Options Committee. Montreal Protocol On Substances that Deplete the Ozone Layer, January Stakeholder feedback Source : Gram 73 Source: Foster 74 Source: Arthur D. Little Inc, Energy Savings Potential for Commercial Refrigeration Equipment, US DOE, 1996 and MARK ELLIS & Associates, Self-Contained Commercial Refrigeration, Australian Greenhouse Office, 2000 and MARK ELLIS & Associates, Remote Commercial Refrigeration, Australian Greenhouse Office, Source: Foster, Gram, Infrico Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 61

356 In service cabinets with solid doors, the duty cycle of the lighting system can vary from 0.5 to 1 hour per day, depending on how long the cabinet is open every day. With such duty cycles the electricity consumption for lighting represents less than 0.5% of the total electricity consumption of service cabinets 64. These values can vary depending on the service cabinet s design: some glass door cabinets might have the lights on even if the door is closed. A service cabinet might include 1 or 2 incandescent light bulbs (around 25 W) inside the cabinet which operate when the door is opened. Efficient lighting systems may provide electricity savings; however, these are expected to be negligible (considering the low share of electricity consumed by the lighting system) Component use pattern, energy consumption and saving potential The table below describes two products component use patterns and energy consumption. Table 4-13: Average working hours of components and their energy consumption for plug in service cabinets Component Average Energy consumption per day (kwh) Model 1 76 Model 2 77 Hours per day (h/d) Average Energy consumption per day (kwh) Hours per day (h/d) Compressor Evaporator fans Condenser fans Anti-condensation heaters Defrost N.A Lights N.A N.A. Control N.A. N.A TOTAL N.A.: Not Available (i.e. no data provided) The data in Table 4-14, based on literature and stakeholder feedback, summarises for each component the percentage of total energy consumption of the service cabinet, the energy saving potential of the component and the energy saving for the overall product. 76 Reference: Mark Ellis & Associates, National Appliance and Equipment Energy Efficiency Program, Analysis of Potential for Minimum Energy Performance Standards for Self-Contained Commercial Refrigeration, Final Draft Report March 8th, Available at < (24/11/2006) 77 Source: stakeholder 62 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

357 Table 4-14: Service cabinet component energy consumption and improvement potential Component % TEC % improvement potential for % improvement potential for product component Evaporator fans * 2-5 Compressor Condenser fans Expansion device N.A Lighting 0.5 N.A. N.A. Defrost 6 N.A. N.A. Anti-condensation N.A heaters Insulation - - 2** TOTAL N.A.: Not Available (i.e. no data has been found) -: no energy consumed by component *By replacing shaded pole motor by an electrical commutated motor **Thicker insulation will reduce the energy savings achieved through other components The total improvement potential suggested here must be seen as overstating the potential savings, as some component improvements will overlap, but the figures compare roughly with an overall estimate provided by stakeholders of 33% energy efficiency achievable for plug-in service cabinets in the year As described in Task 2, the product use pattern corresponds to 8760 hours/year the product is left on constantly. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 63

358 BLAST CABINETS Product description at component level Preliminary analysis shows that the typical blast cabinet will be a single-door, plugin model, with a capacity of around 12kg, providing a chilling cycle from +70 C to +3 C in 90 minutes. Figure 4-26 provides a technical drawing for a typical plug-in blast cabinet. Figure 4-26 Typical plug-in blast cabinet and major components 78 In blast cabinets, the refrigeration system is usually located at the bottom of the unit. The evaporator is usually located inside the cabinet housing, at the top. The average model for blast cabinets is assumed to be around 5-6 GN 1/1 trays (20kg of foodstuff capacity in chilling cycle). The average roll-in model has a capacity of two 30 kg trolleys (60kg). Stakeholder feedback and sales data indicate that blast cabinets use a vapour compression cycle and are mainly used for chilling (however the same product can often also be used for freezing). Roll-in and pass-through equipment comprise a small share of the market (accounting for 15%). However, their energy consumption can reach up to 1.15 times that of a cabinet of similar capacity in the same cycle type. Compressor The compressor used within average blast cabinet is a hermetic reciprocating one with the capacity of 969W and power of 813W. The weight of the compressor is usually between 10 to 14 kg. The compressor is normally located at the bottom of the blast cabinet (see Figure 4-26). As in all vapour-compression based refrigerating equipment, this component is estimated to represent a significant share of the total electricity consumption of blast cabinets (60-80%). 78 Cervino 10 Spare Diagram and Spare List 64 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

359 Expansion device The function of the expansion device, and its role on the overall energy efficiency, is described in and Evaporator Evaporator used in the average blast cabinet uses 1 fan with the 254mm diameter and the blade at the 34 angle. The face area of the evaporator is 1470cm 2 and the air flow is around 1400m 3 per hour. The fan motor type is axial sucking and the fan wattage is equal to 160W. The total weight of the evaporating module is 2 kg. Fans are estimated to represent around 30% of the total electricity consumption of blast cabinets. Typical blast cooling devices include one or several evaporator fans in order to provide a rapid cooling process, responding to the need of increased heat removal from the foodstuff inside the equipment in a very short period of time, having high energy consumption as a consequence. The motors of these fans also generate heat that increases the load and hence the energy consumption of the blast cooling device. Condenser The condenser module consists of 1 fan with the 230mm diameter and the blade at the 34 angle. The face area of the condenser is 1000cm 2 and the air flow is around 710m 3 per hour. The fan motor type is axial sucking and the fan wattage is equal to 34W. The total weight of the condensing module is 2.5 kg. Plug-in blast cabinets commonly use air-cooled condensers located at the bottom of the cabinet (see Figure 4-26). Due to a higher cooling load, blast cabinet condensers are bigger than those used in service cabinets. In the case of remote blast cabinets, the condenser is not located within the cabinet itself and it can therefore be either air-cooled, water-cooled, or be attached to an evaporative condenser. Controls The function of an electric defrost system expansion device, and its role on the overall energy efficiency, is described in and Refrigerant For the different capacities of these equipments, different refrigerants are used. Machines with a capacity equal to 50kW or less usually operate with HFC (as R404A or R134a) in the EU. As with service cabinets, HCs can also be used. However, there is a trade-off in that they are highly flammable, such as is the case for R290 and R1270. Other alternatives such as the R245fa (pentafluoropropane) are in development. For the range between 50kW to 200kW, it is possible to use ammonia instead, while for larger capacities freezers ammonia is preferred because of its energy efficiency and reduced direct emissions impacts through leakage. Machines in this capacity range are not common in the market. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 65

360 In recent years, there has been an increment on the use of R-744 (carbon dioxide), mainly responding to the advantage of running the systems at lower temperatures due to the high suction pressure 79. Housing and insulation The function of insulated walls, casing and gasket, and their role on the overall energy efficiency is similar to that of service cabinets, as described in Doors in blast cooling devices are not opened during the blast cooling process. Instead, doors are opened at the beginning and at the end of the process Component energy consumption, use pattern and saving potential Data on blast cabinet component use pattern, obtained from a blast cabinet manufacture, is presented below. As described in Task 2, the use pattern of 5 cycles per day, 220 days per year has been estimated based on comments from stakeholders and it only applies to chilling functioning. Stakeholders also have mentioned that the energy consumption for similar equipment would vary according to the efficiency of these, reaching the same temperature in different time, hence the use of the components is not standardised. Table 4-15: Average working hours of components and energy consumption for plug-in chilling cycle blast cabinets Component Model 1 Average energy consumption per day (kwh) Hours per day (h/d) Compressor 1.3** Evaporator fans Condenser fans Anti-condensation heaters Defrost* Lights Heated probe *Applicable only to freezing equipment **Per cycle Normally optional The data in the table below, based on literature and stakeholder feedback, summarises for each component the percentage of total energy consumption of the appliance, the energy saving potential of the component and the energy saving for the overall product. Reductions in total electricity consumption are estimated to be possible through the use of traditional options to improve vapourcompression based equipment: with the use of high-efficiency motors in condenser fans and compressors, and thicker insulation. 79 Source: UNEP. Report of the Refirgeration, Air Conditioning and Heat Pumps Techinical Options Committee. Montreal Protocol On Substances that Deplete the Ozone Layer, Januayr Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

361 Table 4-16: Blast cabinet component energy consumption and improvement potential Component Blast cabinets % of total energy consumption of the appliance Improvement potential (in % of the energy consumption of the component) Improvement potential (in % of total energy consumption of the appliance) Evaporator fans (motor) Compressors (motor) Condenser fans (motor) Expansion device Electric defrost (freezers only) 6 N.A. - Insulated walls * TOTAL N.A.: Not Available (i.e. no data has been found) -: no energy consumed by component * Approximated thicker insulation will reduce the energy savings achieved through other components The total improvement potential suggested here compares with an overall estimate of 33% energy efficiency achievable for plug-in blast cabinets in the year 2025, provided by stakeholders, although some component improvements will overlap. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 67

362 WALK-IN COLD ROOMS Product description at component level Preliminary analysis shows that typical walk-in cold rooms rely on compression technology. Sales data indicates that walk-in cold rooms are both plug-in (45%), and remote, with some remote connected to packaged condensing units and others to central refrigeration plants. Compressor The compressor used within the average walk-in cold room is assumed to be hermetic and reciprocating with capacity of 560 W and total weight of 20 kg. The compressor is the component with the highest electricity consumption (it may represent over 50% of the overall energy consumption) 80. Hermetic compressors can be used for duties of up to around 7kW, depending on temperature and pipe run. Semi-hermetic and scroll can be used above this, with scrolls being used up to around 15 to 20kW, and with semi hermetic being more commonly used in larger systems. Scrolls can only really be used high temperature applications from around 5kW, and semi-hermetic from around 2.5kW. Regarding applicability of digital scroll compressors stakeholders stated that these are only available on sizes from around 5 to 14kW on high temperature systems and from 5 kw up to 7.5kW on low temperature systems. There is a general trend toward hermetic compressors 81. Expansion device Using expansion valves with better control (i.e. electronic expansion valves) is estimated to lead to overall electricity savings of up to 18% for remote walk-in refrigerators 80, as they would enable floating head pressure. Evaporator The average evaporator weight is 2.4kg with the fan wattage of 12W. The evaporator is located inside the walk-in cold room, at the top of the product. The function of the evaporator, and its role in the overall energy efficiency of walkin cold rooms is the same as described in Typical walk-in cold rooms include one or several evaporator fans to increase the heat transfer coefficient and achieve an optimal circulation of refrigerated air inside the insulated area. The motors driving the fans can represent around 10 and 17% 80 of the total electricity consumption of walk-in cold rooms for refrigerators and freezers respectively. For walk-in cold rooms, the potential improvement of the evaporator fan motors could lead to a 7 to 8% reduction on overall energy consumption. Further reduction could be achieved through evaporator fan control using a variable speed drive (around 4% reduction) Source: Arthur D. Little Inc, Energy Savings Potential for Commercial Refrigeration Equipment, US DOE, Source: GR Scott, Foster 68 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

363 The positioning of the evaporator is also important. They tend to be located at the centre/rear of the room. In smaller rooms, this may encroach on and reduce internal storage space. Ideally, through better design, the evaporator should be located outside the enclosure or in the centre of the room (although this may have an impact on drainpipe positioning) to maximise storage. Condenser The average condenser weight is 3.5kg with the fan wattage of 20.4W. The function of the condenser in walk-in cold rooms is the same as in refrigeration equipment already described in Plug-in walk-in cold rooms typically use fan assisted air-cooled condensers. In the case of remote walk-in cold rooms, water-cooled or evaporative condensers might be used. Typically, condenser fans represent about 13 and 20% of the walk-in cold room s total electricity consumption for freezing equipment, and refrigerating equipment respectively. Condenser fan motor controls using variable speed drive can be used in order to achieve up to 7% and 2% of energy consumption reduction for freezer and refrigerated walk-in cold rooms respectively 80. Controls Just as in service cabinets, anti-condensation systems (used to avoid damage of the door gaskets) have a direct impact on electricity consumption, not only by their power demand but also because they represent an extra source of heat to be absorbed by the refrigeration system. Frost can alter the heat exchange process at the evaporator and reduce the energy efficiency of the walk-in cold room. Defrost devices can be used to heat the walkin freezer evaporator coils at regular intervals to avoid frost build-up. The electric defrost electricity consumption can represent around 3% of the overall energy consumption of freezing appliances. Defrost systems can be controlled, eliminating unnecessary defrost cycles. The most efficient controls are on-demand types. They start the defrost cycle depending on the temperature or pressure drop across the evaporator or by measuring frost accumulation and sensing humidity 82. However, these are not commonly used in walk-in cold rooms 83. Stakeholders estimate that the use of efficient defrost systems could allow savings around 1 to 2%. Refrigerant For storage temperatures between -4 C to +6 C the typical refrigerants employed are often R-134a and R-404a. For lower temperature requirements, the refrigerant used is typically R-404a. There are also packaged refrigeration units using R290 available on the market 84, and CO 2 is also being used for cold rooms in catering facilities Source: Mark Ellis, Startegies to increase the energy efficiency of non-domestic refrigeration in Australia & New Zealan, Source: Defra 84 Zanotti uniblock 85 CCS Refrigeration and Iglu Cold System. Source: Shecco Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 69

364 Housing and insulation 86 Insulating enclosure Insulation panels are the main components of the insulated enclosure. The function of the insulated panels is similar to that discussed for service cabinets ( ). By increasing insulation thickness, energy savings are estimated to be achievable 87. Panels are normally formed in a sandwich style, with a central portion of insulating material (either foamed into place or as a slab) between two sheets of metal (acting as a thermal break) and with an external finish (can be a variety of materials). Every producer may have different typical sizes according to their production and panels shape; for one producer, a typical panel size may be 1200x2000x60mm, but for another producer it may be 800x1800x80mm, depending on how the producers developed the design of its products. Typical sizes of panels are in the region of 2.3m high, by 1.2m width for smaller walk-in cold rooms. There are many thicknesses, with 80mm stated as common for higher temperature applications (>0 C) and 100mm for low temperatures ( 0 C). Predominantly thicknesses are manufactured at 60mm, 80mm, 100mm and 120mm, but many other thicknesses are used (from 50mm to 200mm). Self-supporting panels have maximum spans, which limit the size of self supporting rooms (constructed without the support of an additional frame); ceiling panels are no longer self supporting when cold room dimension is such that it requires two or more panels to cover the whole ceiling span. In this case it is necessary to use external or internal supporting systems. For example, 80mm thick panels ceiling spans are approximately 4500mm max (and 6400mm high). 100mm thick panels can have a ceiling span of 6000mm (and 9100mm high). External or internal supporting systems are studied on a case by case basis, to best fit the cold room requirements (the conditions under which it will be used), and characteristics of the building in which the cold room is to be assembled, hence may be required for smaller rooms in certain cases. Wall and ceiling panels are usually identical, while floor panels have a typical antislip finish and may have specific internal reinforcement to withstand the supported or transiting loads. Floor panels are made of several layers: An external layer: metal sheet (the same as wall and ceiling panels) The core material: there are several types of floor panels, which every producer may make in different ways. The core material is PUR but on the internal side there may be reinforcement, such as a chipboard panel glued to the internal side metal sheet. An internal layer (the side which is walked upon): a metal sheet, which is specifically used only for floor panels (usually have an anti-slip finish). 86 Source: Fermod, GR Scott, Assofoodtec (IT) 87 Source: Arthur D. Little Inc, Energy Savings Potential for Commercial Refrigeration Equipment, US DOE, 1996 and MARK ELLIS & Associates, Self-Contained Commercial Refrigeration, Australian Greenhouse Office, 2000 and MARK ELLIS & Associates, Remote Commercial Refrigeration, Australian Greenhouse Office, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

365 U value (W/m 2.K) Some producers may replace the internal metal sheet with other materials, such as phenolic plywood Examples displaying the different layers: Phenolic plywood, then PUR/PIR, then a metal sheet. Metal sheet with anti slip finish paint, chipboard, PUR/PIR, metal sheet. For small cold rooms, extruded polystyrene might be used as a layer in the floor panel. Insulation panels are typically PUR and have a λ value of between 0.02 and W/m.K 88. Table 4-17 below shows the typical thicknesses available currently on the market according to the application temperatures ranges. Table 4-17: Typical thicknesses and estimated U-values of insulation panels for walk-in cold rooms 89 Walk in cold room panel thickness (mm) U-value (λ = W/m.K) (W/m².K) Walk-in cold room storage temperature ( ) (Freezer) 75 < mm < < U < (Freezer) 100 < mm < < U < Figure 4-27 below provides other examples of the range of thicknesses and λ values of insulation panels available on the market Manufacturer 1 - PIR 0.3 Manufacturer 2 - PUR, free of ODP agents 0.25 Manufacturer 3 - PUR, free of FCCs 0.2 Manufacturer Insulation thickness (mm) Manufacturer 5 Figure 4-27: Thicknesses and U values of insulating panels available on the market 88 Source: GR Scott, INCOLD 89 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 71

366 Ambient infiltration is affected by the method of fastening the insulation panels together. Cam-lock type mechanisms are commonly used to improve seals (compared to the less effective angled or butted type joints) and hence reduce air infiltration from the (usually) warm and humid external ambient into the refrigerated space, reducing load on the refrigeration system and defrost frequency. Pressure relief valves are also used; if not correctly sized, internal and external pressures can affect the room. Entrances to the storage space The door s effect on the energy consumption of walk-in cold rooms is significant, although the quality, design and user behaviour have a greater impact. Nevertheless, in walk-in cold rooms, doors can be closed while an end-user is collecting cooled items within the room to maintain the integrity of the insulating enclosure and reduce infiltration of ambient air. Panels and doors can be manufactured by the same company, but sometimes are not. For example, some smaller producers may not be equipped to produce doors. Strip door curtains and automatic door closers can help to further reduce infiltration of air. Strip door curtains are more commonly used, and are rows of overlapping clear flexible strips, often fabricated from PVC, which are hung over the opening of a walk-in refrigerator or freezer. They allow passage into and out of the refrigerated space while reducing ambient air infiltration when the door is open. However, these can be an annoyance to operators and considered by some to be a hygiene problem. Hinged doors are the most common and popular (estimated at 70% of the market 90 ), particularly on small cold rooms, but sliding doors are also available. An average door is estimated as having dimensions of 800x1900mm high. Slam-faced doors, also known as plant-on doors, are positioned on the outside and overlap the door opening. This method is generally preferred as it is easy to fit and overcomes problems of mis-alignment of door openings. Flush and semi rebated doors are less popular, but tend to be higher quality. They are more difficult to fit on site, as levels need to be exact and panels need to be plumb, otherwise doors will not fit. Any future settlement would also cause a problem. With cam-locked units, the door frame is manufactured as part of a panel when foamed. To save materials the flush type can also be cut from the main panel itself, which may cause problems if not sealed effectively. Sliding doors are usually manual but can be easily automated. They are common even in small walk in cold rooms and have the advantage of being suitable where a hinged door would encroach on walkways or were access is generally restricted. Usually they are fitted with a manual track, which relies on the operator physically closing the door. Doors in walk-in cold rooms can have security systems in order to avoid users getting locked inside the insulated compartment. Manual operation is available should the need arise, access is available in a variety of ways such as push buttons, pull cords, radars, radio control, etc. 90 Source: GR Scott 72 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

367 Types of doors include: Doors cut from a panel: in this case the door leaf is cut from a typical insulation panel (equipped with adequate reinforcement metal plates, to fix ancillaries) and the remaining part of the panel will form the door frame. Doors with frame: the door leaf is directly foamed in a specific production line, completed with its aluminium profiles (gaskets and ancillaries are however usually added after door leaf is foamed). In this case the door frame is prepared separately using PVC profiles, usually internally reinforced with a steel tube or other material. Door insulation if therefore sometimes the same as wall panels, but other materials are also used: Aluminium profiles for door leaf. Metal sheets (pre-painted). Gaskets made of PVC or other material. PVC (usually internally reinforced) or other material for door frame. Typical insulation properties 91 for doors (the worst case has been assessed for these and worst data are quoted) cut from a panel are: Hinged door (60mm thick) = 0,65W/m 2 K Sliding door (60mm thick) = 0,80W/m 2 K Typical insulation properties for doors with a frame: Hinged door (68mm thick) = 1,16W/m 2 K Sliding door (68mm thick) = 1,15W/m 2 K Gaskets play an extremely important role by creating an insulated seal around the door. Depending on the intended working temperature of the cold room, doors are also equipped with a heating cable around the frame to avoid the build-up of ice and freezing of the gasket. Transparent sections Some walk-in cold rooms incorporate glass sections on their doors or wall panels (estimated market share of 1 to 5% 92 ). Normally, the way windows are installed in cold room walls is the same as a glazed section may be installed on a door; usually doors glazed sections are smaller than windows on a wall panel 93. Entirely transparent doors may be available on request, however normally transparent doors producers are not cold room producers. Insulated glass typically has a U value of 2.9 W/m².K. Lighting 91 Source: Assofoodtec 92 Source: GR Scott, Smeva 93 Source: Incold Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 73

368 Historically, typical walk-in cold rooms include incandescent (estimate of approximately 200W) lighting or fluorescent lighting 80. Its duty cycle can vary from 12 to 14 hours per day, depending on end-user behaviour. With such use, the electricity consumption for lighting represents less than 3% of the total electricity consumption of walk-in cold rooms. Efficient lighting systems may provide electricity savings. However, these are expected to be low; around 1% reduction of the overall energy consumption of the walk-in cold room 80. Lighting is designed according to customer specifications; a standard value for lighting in working environments is regulated by EN : Component energy consumption, use pattern and saving potential The data in the table below, based on literature and stakeholder feedback, summarises for each component the percentage of total energy consumption of the appliance, the energy saving potential of the component and the energy saving for the overall product. Component Table 4-18: Walk-in cold room component energy consumption and improvement potential % of total energy consumption of the appliance Improvement potential (in % of the energy consumption of the component) Improvement potential (in % of total energy consumption of the appliance) Evaporator fans (motor) Compressors (motor) Condenser fans (motor) Expansion device Lighting 2 1 <0.1 Electric defrost (freezers only) <0.1 Thicker insulation * Door - - N.A. Anti-condensation system N.A N.A N.A TOTAL N.A.: Not Available (i.e. no data has been found) -: no energy consumed by component *Approximated thicker insulation will reduce of energy savings achieved through other components The total improvement potential suggested here compares with an overall estimate of 39% energy efficiency achievable for plug-in walk-in cold rooms in the year 2020, provided by stakeholders, although some component improvements will overlap. As described in Task 2, the product use pattern corresponds to 8760 hours/year the product is left on constantly. 74 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

369 PROCESS CHILLERS Product description at component level Process chillers are refrigerating products, therefore, depending on the technology used, they include the refrigeration components described for either the vapourcompression or absorption technologies. Absorption technology is discussed further in Task 5, in (this technology is not used widely in EU). The average model for process chiller working at medium temperature was suggested by the industry to present approximately 260kW of cooling capacity. According to different stakeholders 94 the average chiller capacity could be 220kW. The latter will not be considered as the average in the scope of ENTR Lot 1. In order to reach low and medium temperatures, the water used in the chiller is mixed with Ethylene glycol or propylene glycol. The efficiency of the equipment will decrease with the increase of the concentration of this substance. Another factor affecting the efficiency corresponds to the differential of temperature. The Base Case would provide a cooling capacity about 45% higher if used to cool pure water at +7 C. Compressor Process chillers can easily be classified depending on the kind of compressor used: centrifugal, screw, scroll and reciprocating. The choice depends mainly on the cooling capacity range and operating conditions. According to the answers in the second questionnaire, the average process chiller is also equipped with semi-hermetic screw compressors. Expansion device According to the answers in the second questionnaire, the average process chiller for low temperatures is equipped with an electronic expansion valve (EXV). Evaporator According to the answers in the second questionnaire, the average process chiller uses a direct expansion system. The evaporator technologies used in packaged chillers are: shell and tube heat exchanger, braze plate heat exchanger, tubular heat exchangers where the water can be outside the heat transfer tube. These technologies will be discussed in Task 5. Shell and tube 95 evaporator type is the most commonly used for larger chillers. Condenser According to the answers in the second questionnaire, the average process chiller for low temperatures is water-cooled. Air-cooled process chillers are generally used in applications where the additional heat they discharge is not a factor. They require less maintenance than water-cooled units and eliminate the need for a cooling tower and condensed water pump. They generally consume approximately 94 Defra study 95 A type of evaporator involving a nest of tubes within a baffled shell Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 75

370 10% more power than a water-cooled unit as a wet surface will transfer heat better than a dry surface. For example, according to ASHRAE Standard , for compression technology, similar capacity chillers using water-cooled condensers should have EER 96 around 50% higher than those using air-cooled condensers. For absorption technology, similar capacity chillers using water-cooled condensers should have EER around 400 higher than those using air-cooled condensers. However, in ASHRAE the energy of water cooled condenser pumps is not taken in account. The technologies used for water cooled condenser are: tube in tube, brazed plate heat exchanger or tubular heat exchanger with the water inside the heat transfer tube and semi-welded (the water needs to be cooled either in a cooling tower, or in a dry cooler). For air cooled condenser, the technology widely used is the coil type refrigerant inside the tube. As emerging technology, the micro-channel heat exchanger has been introduced. There is a size limitation for packaged air-cooled process chiller of between 1500 to 1800 kw cooling capacity. For bigger capacity, water-cooled is usually used. Pump Stakeholders have mentioned that this is not normally included in the packaged equipment, but can be required to drive the water through the cooling system in water-cooled models. Also, in some models, a condenser pump interlock is included to prevent refrigerant pressure falling too far during the off cycle, thus providing energy savings via pump shutdown. Depending of the complexity of the cooled water circuit, a single circuit (primary circuit) for the chiller and a secondary circuit for the customer are used. Due to poor installation, the actual performance of the water pumping system might be as much as 28 to 56% lower than the performance claimed by the manufacturer. 97 Controls The control system of a process chiller should provide motor protection, avoid high pressure, loss of refrigerant, loss of water flow, freeze protection and low refrigerant pressure. Controls shall include motor switch, electricity switch in case of failure, chilled water set-point adjustment, operation indicators (temperatures and pressures), among others features. Refrigerant 98 The refrigerant used in chillers has a strong relation with the type compressor employed. Chillers equipped with positive displacement compressors: 96 Energy Efficiency Ratio (EER) - a ratio of the cooling capacity in Btu/h to the power input values in watts at any given set of Rating Conditions expressed in Btu/(W h) 97 M. Merchat, Mesure des performances énérgétique des systémes de refroidissement, Source: UNEP. Report of the Refirgeration, Air Conditioning and Heat Pumps Techinical Options Committee. Montreal Protocol On Substances that Deplete the Ozone Layer, Januayr Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

371 Screw chillers initially employed R-22 (mid-1980s). The trend of recent years has been substituting this refrigerant for R-134a. In Europe, especially in northern countries, an increase on higher pressure R-410A chillers has been evidenced over the past years. Scroll chillers refrigerants features R-134a, R-410A and R-407C. In countries where R-22 has been phased out by regulations due to the Montreal Protocol, the use of R-407C has increased. For the new scroll chillers, R-410A is being used. R-744 is being used by several manufacturers all over the world; however, it is not yet common 99. Prior the Montreal Protocol, smaller reciprocating chillers were using R-22 and R- 12, being the first one the most preferred. The bigger reciprocating chillers were offered with R-22 as well. After the advent of Montreal Protocol, the refrigerant choice has shifted almost completely to R407C, and in a small extent to R-134a, R- 290 (propane) or R-1270 (propylene). For water-cooled chillers it is possible to use ammonia as refrigerant, but these units are smaller compared to fluorocarbon ones. Chillers equipped with centrifugal compressors: Prior to 1993, this kind of chillers was offered with R-11, R-113, R-12, R-114, R-500, and R-22 refrigerants, being the R-11 by far the most common due to its efficiency. After 1993, as consequence of the Montreal Protocol, production of CFCs or CFCs containing refrigerants was ended in developed countries. From this date, CFC-11 was replaced by R-123, while R-12 and R-500 were substituted by R-134a. The capacities for centrifugal chillers related to the used refrigerant are shown in table below) Housing Table 4-19: Centrifugal chillers refrigerants capacity Refrigerant Capacity range (kw) R ,000 R ,000 R-500 3,500 5,000 R-22 2,500 35,000 R ,000 R-134a ,000 R-245fa 2,600 9,200 R-744 No limits identified This component is not relevant to all process chillers. Some incorporate a housing to protect from the environment, while giving a support to fans in the case of aircooled. Normally, water-cooled chillers do not use housing Component energy consumption, use pattern and saving potential The data in the table below, based on literature and stakeholder feedback, summarises for each component the percentage of total energy consumption of the appliance, the energy saving potential of the component and the energy saving for the overall product. 99 Source: ECOS Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 77

372 According to feedback from stakeholders, the average chiller works at 80% load. Information on Base Case component working hours has not been provided. Table 4-20: Process chiller component energy consumption and improvement potential Component % of total energy consumption of the appliance Improvement potential (in % of the energy consumption of the component) Improvement potential (in % of total energy consumption of the appliance) Evaporator (pumps) 8.5 to to to 1.4 Compressor to to 13 Condenser fans to to 1.4 Expansion device N.A. - N.A. TOTAL Approx. 15 N.A.: Not Available (i.e. no data has been found) -: no energy consumed by component 1 Tipically not included in the equipment The improvement factors are also linked with the selection and the energy management of the pumps for example. The total improvement potential suggested here compares with an overall estimate of 30% energy efficiency achievable for packaged process chillers in the year 2020, provided by stakeholders, but this includes potential improvements such as floating head pressure, which the component analysis above does not. As described in Task 2, the use pattern corresponds to 4,380 hours/year (365 days/year, 12hrs/day). This use pattern considers equipment working in industrial processes. Stakeholders has expressed that the use pattern for appliances working in refrigeration would be on during 24 hours per day and 365 days per year, working at 80% load. 78 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

373 REMOTE CONDENSING UNITS (RCUS) Product description at component level As shown in Task 2, the most commonly used RCUs are air cooled and consist of a compressor, condenser coil, fan, motors, refrigerant reservoir, and operating controls. Most of the condensing units have cooling capacities between 3-20 kw and capacities higher than 100 kw are only used for large systems. Compressor The compressor most commonly used within the equipment is a reciprocatingtype, hermetically sealed, with rubber vibration isolators. The motor is an on-off type and includes start capacitor, relay, and contactor. The main factor affecting the energy consumption levels of the compressors is the differences between individual compressor units and parallel compressor units. Variable speed drives for compressors allow for greater flexibility in meeting part refrigeration loads. Moreover switching from electric motors to engine-driven open compressors may also achieve savings. Condenser The average condenser coil used in remote condensing units is made of a seamless copper tube and aluminium fin coil. The condenser fan is made of aluminium. Moreover, three types of condensers might be used in the RCU: air-cooled, watercooled or evaporative condensers. Air-cooled condenser fans and water-cooled condenser pumps may provide opportunities to reduce energy consumption. Increased heat exchanger size, minichannel heat exchangers and variable condensing temperatures can also achieve energy savings. Controls In the average equipment, the controls to switch on and off the compressor when it is not needed are mechanical thermostats with no energy consumption in standby mode. Electronic thermostats are used in compressors with VSD technology, or condensing units with parallel compressors, with 1-2 W of power input. Refrigerant Remote condensing units normally use R-404A as refrigerant in Europe. In some cases, R-507A or R-410A are employed as well. R-134a is also used, but R-404A is the leading choice because of the lower cost of the condensing units to obtain the same cooling capacity 100. Market penetration of low-gwp condensing units in developed countries is 1-2% for CO2 and 3-5% for R290. Condensing units are the most difficult equipment to use low-gwp refrigerants because the market is driven by cost. CO 2, ammonia and hydrocarbons have been tested and applied, but 100 Source: UNEP. Report of the Refirgeration, Air Conditioning and Heat Pumps Techinical Options Committee. Montreal Protocol On Substances that Deplete the Ozone Layer, May 2010 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 79

374 the number of these in the market is low. New designs emerged using ammonia, even for small condensing units 101. Housing Packaged condensing units are constructed within metal or plastic housings for protection from dust and weather. Units located outdoors require better insulation for protection from water, whereas in indoor units insulation is not that important. In both cases the interior of the condensing unit has to be easily accessible for installers or technicians, in order to facilitate the maintenance of the components Component energy consumption, use pattern and saving potential The data in the table below, based on literature and stakeholder feedback, summarises for each component the percentage of total energy consumption of the appliance, the energy saving potential of the component and the energy saving for the overall product. Table 4-21: Remote condensing unit component energy consumption and improvement potential Component % of total energy consumption of the appliance Improvement potential (in % of the energy consumption of the component) Improvement potential (in % of total energy consumption of the appliance) Compressor Condenser fans/pump (motor) TOTAL N.A.: Not Available (i.e. no data has been found) -: no energy consumed by component The total improvement potential suggested here compares with an overall estimate of 23% energy efficiency achievable for remote condensing units in the year 2020, provided by stakeholders. As described in Task 2, the use of the condensing unit depends on the product it is connected to, hence could vary from 1,650 for a blast cabinet to 8,760 for a walkin cold room). The industry standard for the duty cycle is 16h/day, according to information provided by stakeholders. This means 5840h/year. 101 Sanden Corporation (Japan). Source : Shecco 80 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

375 SUMMARY This section described the average product parameters, Base Case technical specifications and an analysis of improvement potential by component. The Base Cases were selected as the most representative models on the market. The calculated and stakeholder estimates for saving potentials for the product groups are described in the table below, and apart from the figures for process chillers, these are approximately equivalent (the saving potentials calculated through components do not take into account potential overlaps e.g. improved insulation will reduce savings achieved though other components therefore are over-estimated). Type of equipment Table 4-22: Comparison of energy saving potentials Calculated potential energy savings by component (%) Stakeholder estimates of potential energy savings in 2020 (%) Service cabinets Blast cabinets Walk-in cold rooms Process chillers Remote condensing units Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 81

376 4.8. BASE CASE TECHNICAL SPECIFICATIONS For each product group, the Base Case used for the environmental analysis is represented by one or two weighted Base Cases, calculated using the market shares of the different configurations and various assumptions on relative energy consumption, material quantities and other factors, as described below. This leads to an abstract model, not comparable to any specific product in the market, but useful as a statistical tool to calculate overall market impacts. The characteristics described below for these weighted Base Cases are those essential for the EcoReport assessment. These weighted Base Cases have been developed from one or two sub-base Cases (details provided in Annex 4-1), and these sub-base Cases are comparable to the most common product configuration on the market, with differentiation of low, medium or high temperature, where necessary. The sub-base Cases are necessary, in order to have real product characteristics from which to extrapolate the weighted models, and also to compare against BAT in the following Tasks. However, for the environmental impact assessment and the EU stock energy savings calculations, the weighted Base Cases will be used. A sensitivity analyses for each weighted Base Case was undertaken, and the results of these are presented in SERVICE CABINETS For the case of service cabinets, two weighted Base Cases have been developed corresponding to the different operation temperature (medium and low temperature). The details of the real model on which some of the Base Case specifications are based are provided in Annex 4-1, Assumptions used are as follows: energy consumption based on 450 litre net internal volume 102 model, climate class 4, M-package temperature class M1, extrapolated as shown in Table AEC of LT product assumed to be HT multiplied by 2.5, and LT materials in the product are assumed to be equal to that of HT multiplied by 1.1. a market weighted AEC was then calculated, using the market shares as described in Table 4-23, for the high-temperature refrigerator and another for low-temperature freezer. price of HT model assumed to be 1, , and 1,100 for LT. on average, the lifetime and distribution volume is assumed to be equal to that of the 450 litre net internal volume model described above. 102 Calculated according to EN 441 method 103 Stakeholder comments that AEC for an average M1 product should be around 2000 kwh/year. Source: Electrolux, Foster, Gram 104 Source : Defra, Foster 82 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

377 products are assumed to be 100% plug-in type (remote represent less than 2% of the market) and refrigerator-freezers are not included (also represent less than 2% of market). refrigerant R134a used in HT, charge 300g, and R404A used in LT, charge 400g. refrigerant leakage is estimated to be 1% per annum, and loss at end-oflife 100% of remaining refrigerant in the circuit. The sensitivity of the control instrumentation normally used at the end of the production line is set at 3%, hence the worst-case leakage rate is below this. During the life no recharge of refrigerant is planned (this would be considered as a product failure and would influence directly the service call rate, i.e. quality index, of the product 105. Total lifetime leakage is therefore estimated to be 100% of original charge. installation cost is zero. maintenance and repair cost is 10% of the weighted Base Case price. Table 4-23: Estimated energy consumption weighting factors for service cabinets Configuration Operation temperature Model type: door numbers Estimated average internal volume (litres)* Market share (%) Vertical Refrigerator Freezer Horizontal Refrigerator Freezer Chest Freezer *Calculated according to EN 441 method Assumptions 2,000 kwh per annum consumption (Provided by stakeholders) Consumption per litre is 0.8x that of 1-door vertical refrigerator Consumption per litre is 2.5x that of 1-door vertical refrigerator Consumption per litre is 0.95x that of 1-door vertical freezer Consumption per litre is 1.35x that of 1-door vertical refrigerator Consumption per litre is 0.8x 1-door horizontal refrigerator Consumption per litre is 1.05x that of 1-door vertical freezer Consumption per litre is 0.95x 1-door horizontal freezer Consumption per litre is 0.8x that of 1-door vertical freezer Average AEC of Base Case sub-categories (kwh) 2,000 3,200 5,000 9, ,167 2,217 3, Source: Electrolux Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 83

378 In Table 4-24 below, the main characteristics selected for the weighted service cabinet Base Cases are presented. Table 4-24: Characteristics of the service cabinet weighted Base Cases Product characteristics Weighted Base Case MT Weighted Base Case LT Test standard EN 441 EN 441 Functional unit: Litre of net volume at +5 C Litre of net volume at -18 C AEC [kwh/year]: 2,000 5,000 Price (ex VAT) [ ]: 1,000 1,100 Lifetime [years]: Weight of product [kg]: Shipping volume [m 3 ] : Refrigerant: R134a R404A Refrigerant charge [g]: Refrigerant leakage [% per annum]: BLAST CABINETS Configuration Reach-in For the case of blast cabinets, a single weighted Base Case has been developed corresponding to the different types of equipment (chilling, freezing and chilling/freezing) and the different configuration (reach-in, roll-in and passthrough). The technical specifications of the real model on which this is based are provided in Annex 4-1, Assumptions used for the weighted blast cabinet Base Case are as follows: The weighting was done considering all configuration: roll-in, reach-in and pass-through. Remote units are considered to be 15% of the total market, the rest plugin. Market distribution considered for all categories as per Task 2. Materials proportions and weights used were not weighted for all categories of the stock. Instead, the material proportion used is the equivalent to the most commonly sold equipment in the EU (20kg capacity reach-in). Use pattern varies for chilling equipment ( minute cycles per year), freezing ( minute cycles per year) and combined models ( minute cycles plus minute cycles per year). The weighted Base Case use pattern is an abstract figure, calculated by weighting the assumed used patterns of all product types by their respective market shares. The energy consumption per category is based on the assumed factors as shown on the table below. Table 4-25: Estimated energy consumption weighting factors for blast cabinets Operation temperature Chilling Size Location of condensing unit Market share (%) Assumptions Average AEC of Base Case subcategories (kwh/year) Small R Plug-in energy cons. as reached-in medium 528 (Base) Medium R Plug-in 4.21 (Base) Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

379 Configuration Roll-in (trolley) Operation temperature Freezing Chilling / Freezing* Chilling Freezing Chilling/ Freezing* Size Location of condensing unit Market share (%) Large R Plug-in 0.77 Extra-large R Remote 0.77 Small Plug-in 0.26 Medium Plug-in 0.43 Large Plug-in 0.09 Extra-large Remote 0.09 Small Plug-in Medium Plug-in Large Plug-in 7.65 Extra-large Remote 7.65 Small Plug-in 0.06 Medium Remote 0.03 Large Remote 0.02 Small Plug-in 0.06 Medium Remote 0.03 Large Remote 0.01 Small Plug-in 5.88 Medium Remote 2.94 Large Remote 0.98 Pass-through Chilling Small Plug-in 0.03 Assumptions 2.40 energy cons. as reached-in medium (Base) 3.8 energy cons. as reached-in medium (Base) 2.5 energy cons. as reached-in small (Base) 2.5 energy cons. as reached-in medium (Base) 2.5 energy cons. as reached-in large (Base) 2.5 energy cons. as reached-in extra-large (Base) Aggregate energy cons. from chilling and freezing cycles* Aggregate energy cons. from chilling and freezing cycles* Aggregate energy cons. from chilling and freezing cycles* Aggregate energy cons. from chilling and freezing cycles* 1.15 energy consumption of cabinet of similar capacity 1.15 energy consumption of cabinet of similar capacity 1.15 energy consumption of cabinet of similar capacity 2.5*1.15 times energy consumption of cabinet of similar cap. 2.5*1.15 times energy consumption of cabinet of similar cap. 2.5*1.15 times energy consumption of cabinet of similar cap. Aggregate energy cons. from chilling and freezing cycles* Aggregate energy cons. from chilling and freezing cycles* Aggregate energy cons. from chilling and freezing cycles* 1.15 energy consumption of cabinet of similar Average AEC of Base Case subcategories (kwh/year) 2,112 3, ,100 2,640 4, ,540 3,696 5,852 4,148 6,219 10,102 5,185 7,774 12,628 7,259 10,883 17,679 4,148 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 85

380 Configuration Operation temperature Size Location of condensing unit Market share (%) Assumptions capacity Medium Remote energy consumption of cabinet of similar capacity 1.15 energy consumption Large Remote 0.01 of cabinet of similar capacity 2.5*1.15 times energy Small Plug-in 0.03 consumption of cabinet of similar cap. 2.5*1.15 times energy Freezing Medium Remote 0.02 consumption of cabinet of similar cap. 2.5*1.15 times energy Large Remote 0.01 consumption of cabinet of similar cap. Aggregate energy cons. Small Plug-in 2.94 from chilling and freezing cycles* Aggregate energy cons. Chilling/ Medium Remote 1.47 from chilling and freezing Freezing* cycles* Aggregate energy cons. Large Remote 0.49 from chilling and freezing cycles* *User behaviour corresponds to 1chilling cycle of 90min + 1 freezing cycle of 240min Average AEC of Base Case subcategories (kwh/year) 6,219 10,102 5,185 7,774 12,628 7,259 10,883 17,679 The factors presented in the table were provided by the industry. The factor of 1.25 for the relation between remote and plug-in cabinets was revised by stakeholders (Asskuhl, Friginox, Foster, 2010), providing a new factor of 1:1. This is due to the distance between the cabinet and condensing unit decreasing the efficiency, compensating the positive effect achieved by the lower temperature outside the kitchen. The annual foodstuff processing capacity is the total amount of kilograms of foodstuff that can be processed, and has been calculated using the assumed use patterns for each product type, then weighted according to the market proportions, to find an average. The calculated value corresponds to 16,197 kg/year. Expected refrigerant charge is approximately 100 g of refrigerant per 1 kg of foodstuff to be refrigerated. This has been calculated using average charges for each product type, which were then weighted according to their market distribution. Refrigerant leakage was calculated considering the proportion between plug-in and remote equipment, assumed to have leakage rates of 5% and 12% respectively. The End-of-Life dumped refrigerant percentage was weighted considering 50% for remote equipment and 100% for plug-in 106. As result the end-of-life dumped refrigerant is 82%. 106 Source: ECOS, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

381 On average, lifetime, distribution volume and price assumed to be equal to that of a 20 kg capacity model. Installation cost is zero. Repair cost is 10% of price. The blast cabinet is only considered to work during the blast cycles, either chilling or freezing. As expressed in Task 1, storage mode is not the main function of this equipment. In the table below, the main characteristics selected for the weighted service cabinet Base Cases are presented. Table 4-26: Technical characteristics of weighted blast cabinet Base Case Product characteristics Base Case Functional unit: 1kWh/1 kg of foodstuff (referred to material proposed by NF AC D ) AEC [kwh/year]: 3,031 Use pattern: 5.5 hour/day, 220 days/year, in different cycles types Price (ex VAT) [ ]: 6,400 Lifetime [years]: 8.5 Shipping volume [m 3 ] : 1.17 Weight of product [kg]: 120 Refrigerant: R404A Refrigerant charge [g]: 2,800 Refrigerant leakage [% per annum]: WALK-IN COLD ROOMS For walk-in cold rooms, a single weighted Base Case has been developed covering chilling and freezing products, and the different sizes. Assumptions used for the weighted blast cabinet Base Case are as follows: Due to no current measurement standard for walk-in cold rooms and no information provided on annual electricity consumption, AEC is based on UK MTP assumptions, and is weighted across the whole market, including low and medium temperatures (market data in Task 2), based on the average size of 25m 3 internal net volume and weighted AEC of 12,155 kwh. Table 4-27: Estimated energy consumption weighting factors for walk-in-cold room Size MTP MTP MTP MTP estimated Estimated estimated Operation estimated estimated average AEC of average net average temperature market average sub-categories internal cooling proportion COP (kwh) volume (m 3 ) load (kw) Small (up to Chiller 44.49% , m 3 ) Freezer 22.54% , Medium (20m 3 Chiller 23.36% , to 100m 3 ) Large (100m 3 to 400m 3 ) Freezer 8.10% , Chiller 1.13% , Freezer 0.48% , Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 87

382 The room is assumed to be factory-built, with a packaged refrigeration unit. On average, refrigerant charge, lifetime, distribution volume and price assumed to be equal to that of the 25m 3 internal volume model. Refrigerant charge is an approximated average, which takes into account the difference between plug-in and remote charge sizes through weighting (assuming the market is split 45% plug-in and 55% remote). Refrigerant leakage was calculated considering the proportion between plug-in and remote equipment, assumed to have leakage rates of 5% and 12% respectively 115 per annum, and loss at end-of-life of 100% of the refrigerant in the circuit for plug-in and 50% for remote units Annual refrigerant leakage is therefore estimated to be 9%, while end-of-life is estimated as 73% - total lifetime leakage is therefore estimated to be 163% of original charge. Installation cost is 20% of price. Maintenance and repair cost is 10% of price. In the table below, the technical characteristics selected for the walk-in cold room Base Case are presented. Table 4-28: Characteristic of the walk-in cold room weighted Base Case Product characteristics Base Case Functional unit: m³ of net internal volume AEC [kwh/year]: 12,155 Price (ex VAT) [ ]: 8,800 Lifetime [years]: 10 Shipping volume [m 3 ] : 15 (flat-packed) Weight of product [kg]: 1,000 Refrigerant: R404A Refrigerant charge [g]: 3,000 Refrigerant leakage [% per annum]: 9 Further technical specifications of this estimated average chilling model are provided in Annex 4-1, PROCESS CHILLERS For the case of process chillers, two weighted Base Cases have been developed corresponding to the different operation temperature (medium and low temperature). The technical specifications of the real model on which this is based are provided in Annex 4-1, Assumptions used are as follows: the machines considered to generate the analysis are packaged ones. the condensing unit is integrated and condenser is water-cooled. There is more evidence and technical specifications available regarding this model type. the annual energy consumption was weighted considering the typical use pattern, relative energy consumption of different product types, as shown 88 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

383 in Table 4-29, the capacities of the equipment and their market shares. It was assumed that the compressor works during 80% of the cycle. the shipping volume was not weighted. Instead, the volume of the most commonly sold equipment was used for each temperature range. the consumption ratio between the different equipment types are shown in the Table These factors are based on equipment evaluation expressed by the industry. Therefore, the conditions of evaluation are included in the factors, e.g. the difference of inlet temperature between water- and air- cooled chillers. Table 4-29: Estimated energy consumption weighting factors for chillers Type of equipment Relative energy consumption Low-temperature 2.5*X Medium-temperature X Small low-temperature Y Medium low-temperature 4.6*Y Large low-temperature 8.33*Y Extra-large low-temperature 16*Y Small medium-temperature Y Medium medium-temperature 4.6*Y Large medium-temperature 8.33*Y Extra-large medium-temperature 16*Y Air-cooled 1.15*Z Water-cooled Z the equivalent cooling capacity of the equipment was calculated based on the annual consumption corresponding to the different product types and material weights and proportions extrapolated from the BOM of a similar product. The calculated weighted cooling capacity is 266kW for both temperature ranges. This weighted cooling capacity is determined using the average energy consumption per cooling capacity as in Table the energy consumption per category is based on assumed factors shown on the Table After revision of the factors by stakeholders, the original proportion between water- and air-cooled chillers (1:1.4) was reduced to 1:1.15 as an average of the possible European values (1:1 and 1:1.3), for energy consumption (Table 4-29). The calculation is based on market information considering the common cooling capacities and power inputs. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 89

384 Operation temperature Medium Low Table 4-30: Estimated energy consumption weighting factors for process chillers Size Typical capacity (kw) Small 50 Medium 250 Large Small 50 Medium 250 Large 500 Extralarge Extralarge 1000 Cooling system Air cooled Water cooled Air cooled Water cooled Air cooled Water cooled Air cooled Water cooled Air cooled Water cooled Air cooled Water cooled Air cooled Water cooled Air cooled Water cooled Market share (%) Estimated factor Average AEC of Base Case sub-categories (kwh) (-8 C/-15 C outlet temp./ 30 C) Typical COP *X 90, X 78, *4.6*X 405, *X 352, *8.3*X 779, *X 677, *16*X 1,442, *X 1,254, *Y 126, Y 110, *4.6*Y 567, *Y 493, *8.3*Y 1,090, *Y 948, *16*Y 2,019, *Y 1,755, the estimated power input corresponds to 120 and 168kW for medium and low temperature respectively. the estimation of COP was based on the equivalent cooling capacity and the weighted power input. The average COP for medium temperature water-cooled chillers is 2.21, while for low temperature is the outlet evaporator operation temperature is -8 C in the range from - 12 C to +3 C (medium temperature), and -15 C in the range of -25 C to - 8 C (low temperature). the equipment works with ethylene glycol solution at 30%. It has been mentioned by stakeholders that the use of propylene glycol is more suitable for foodstuff refrigeration. However, within the scope of the study, chillers are meant for use in general industrial processes. The presence of additive to the water increases the requirements of power input, as the viscosity of the liquid increases. 90 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

385 based on information from catalogues, there is a charge of 0.35kg of refrigerant per kw of cooling capacity. This ratio was used to determine the refrigerant charge of the two weighted Base Cases. price presented corresponds to around 200 per kw of cooling capacity for medium temperature and around 250 for low temperature. on average, lifetime and distribution volume are assumed to be equal to that of a 260 kw cooling capacity model. installation cost 10% of price. repair cost is assumed to be a 10% of the purchase product price. This cost could be increased depending on the type of refrigerant used due to safety conditions. the environmental conditions change according to the type of equipment. Water-cooled chillers have inlet water at 30 C, while for air-cooled is normally evaluated at 35 C inlet air. This difference is considered within the conversion factor (1.15) provided by the industry, expressed in Table 4-29 and Table The characteristics selected for these two are presented in the Table Table 4-31: Characteristics of weighted process chiller Base Cases Product characteristics Weighted Base Case MT Weighted Base Case LT Functional unit: 1 kw cooling capacity to reach - 8 C at +30 C water temperature 1 kw cooling capacity to reach - 25 C at +30 C water temperature Cooling capacity (kw): AEC [kwh/year]: 420, ,659 Use pattern: 12 hour/day, 365 days/year 12 hour/day, 365 days/year Price (ex VAT) [ ]: 55,000 70,000 Lifetime [years]: Shipping volume [m 3 ] : Weight of product [kg]: 2,667 3,067 Refrigerant: R134a R404A Refrigerant charge [g]: Refrigerant leakage [% per annum]: REMOTE CONDENSING UNITS For the case of remote condensing units, two weighted Base Cases have been developed corresponding to the different operation temperature (medium and low temperature). The technical specifications of the real models on which these are based are provided in Annex 4.1, Assumptions used are as follows: the stock figures used for the EcoReport are slightly different from those shown in Task 2, in order to avoid the double counting of energy consumption of condensing units connected to service cabinets, blast cabinets, or walk-in cold rooms. From the overall stock figures for remote Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 91

386 condensing units found in Task 2, the proportion number of products connected to a remote unit has been subtracted, remaining the stock of condensing units connected to other type of refrigeration equipment. market shares of the different configurations shown in Task 2, and annex 2.9 are used in order to weight the annual energy consumption, coefficient of performance, price and refrigerant charge. Table 4-74 provided in Annex 4.1, shows the weighting factors explained above, together with the Average Energy Consumption and the Average COP of the different configurations. material weights and proportions extrapolated from the sub Base Case (most common product in the market). A sensitivity analysis has been carried out to compare changes if material quantities vary (see results in ). the material of the LT Base Case equals that of MT, increased by 20%. energy consumption for the Base Case model for medium temperature presented in Annex 4.1, has been provided by stakeholders. energy consumption of remote condensing units with twin compressors or more is estimated to be 10% lower than remote condensing units with a single compressor, and represents 5% of the market. a temperature ratio 107 of 1.78 was used to calculate the increase in AEC of Low Temperature remote condensing units compared to Medium Temperature machines. condensing units using scroll, rotary vane and screw compressors are estimated to have annual energy consumption 10% lower than equivalent condensing units with hermetic reciprocating compressors. However, rotary vane compressors are not used in commercial refrigeration equipment. and are not taken into account. condensing units with 2-speed or VSD compressor are estimated to have energy consumption 10% lower than condensing units with on/off compressor water-cooled condensing units have been estimated to have energy consumption 5% lower than air-cooled condensing units lifetime, distribution volume and repair and maintenance costs are assumed to be equal to that of the Base Case model (most common product in the market). Installation and repair costs are 10% of price of the Base Case. the estimated COP values have been calculated by applying to the power input the same savings as in the AEC, and assuming that the cooling capacity is the same. Energy savings related to partial load and seasonal variations (variable speed drive, parallel compressors, floating head pressure) cannot be reflected in the COP tested at one point (EN 13215), and are not included in these calculations. 107 (ambient temp- medium target temp)/(ambient temp- low target temp); (32-(-10))/(32-(-35)) = 1.78; LT = MT* Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

387 The technical characteristics selected for the remote condensing unit weighted Base Case are shown in the following table. Table 4-32: Characteristics of the remote condensing unit weighted Base Cases Product characteristics Weighted Base Case MT Weighted Base Case LT Test standard: EN 13215:2000 EN 13215: kw of cooling capacity at 1 kw of cooling capacity at Functional unit: evaporation temperature evaporation temperature -10 C and ambient -35 C and ambient temperature +32 C temperature +32 C AEC [kwh/year]: 32,330 38,083 COP*: Price [ ]: 5,249 7,419 Shipping volume [m 3 ]: Weight of product [kg]: Refrigerant: R404A R404A Refrigerant charge [kg]: Refrigerant annual leakage [% per annum]: Lifetime [years]: 8 8 * COP: cooling capacity (kw) divided by the power input (kw). Although COP is not required as an EcoReport input, it is included for information. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 93

388 4.9. INPUTS FOR BASE CASE ASSESSMENT This section describes the information required as input for the EcoReport tool, to assess the life cycle environmental impacts of the products LIFECYCLE STAGES Production phase The percentage of each material for the different products was provided by stakeholders through BOMs. The BOM obtained for selected products and components is presented in annex 4-2. The scrap production during sheet metal manufacturing was considered as 5% for all products. Distribution phase The distribution phase in the EcoReport tool is represented by the product type and volume of the packaging. In general packaging consists of plastic, cardboard and a wood palette used to facilitate the transport of the product. This contribution of materials was assumed for all Base Cases. Use phase In this section, the annual energy and resources consumption that can be measured for the product and the direct emissions during product life are discussed. The electrical energy consumption and the direct emissions related to refrigerant use are considered. End of life phase Very little commercial or industrial refrigeration equipment is found in refrigerator recycling plants in EU (less than 1 %). The most common end of life route is dismantling of the cabinet, and recycling of the raw material through specific recycling companies, or via the original manufacturers. The cost is assumed to represent around 1% of the total cost purchase. According to manufacturers, resale of used products has been decreasing, and nowadays it represents less than 1% of appliances. Refrigerant leakage rates The estimation of the refrigerant leakage rates is shown in Table 4-33 below. An annual leakage rate between 1% and 7% has been estimated for plug-in products and between 12% and 15% for remote configurations. In order to carry out the environmental impact assessment on average products representative of the market, these values have been weighted following the market shares shown in Task 2 (also shown in the weighting assumptions in 4.8. above). These leakage values have been multiplied by the number of years of life of the products to obtain the overall refrigerant emissions during their lifetime. The refrigerant emissions during the end of life phase have been estimated in 50% for remote condensing units and chillers 108, and between 73% and 100% for service 108 Source: ECOS, Shecco 94 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 Febru

389 cabinets, blast cabinets and walk-in cold rooms. This was summed up to the fugitive refrigerant during the use phase, to provide a final total lifecycle leakage figure (this can in some cases exceed 100%, where it is assumed that the product has been recharged with refrigerant during its life). Refrigeration roadmap study (UK) BIO estimation before 2 nd SHM SH comments in 2 nd SHM BIO used in sub- Base Cases BIO used in weighted Base Cases Table 4-33: Leakage rates estimations for Base Cases analysis Service cabinets <1% plugin Annual refrigerant leakage rates Blast cabinets <1% plugin Walk-in cold rooms <1% plugin Industrial process chillers Remote condensing units <1% plug-in 10%-20% 1% 1% 1% 1% 1% 10%-12% 10%-12% 10%-12% 10%-12% 15% Plug-in 1% 5% 5% 1% - Remote 12% 12% 12% 1% 15% 6% 7% 9% 1% 15% Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 95

390 DATA INPUTS SUMMARY SC HT SC LT BC WICR CH MT CH LT RCU MT RCU LT Number of BOMs forming Base Case 3 Based on HT 1 Partial 1 Based on MT partial Based on MT Bulk Plastics 6.15% 6.15% 0.96% 3.58% 0.05% 0.05% 2.18% 2.18% TecPlastics 9.48% 9.48% 6.79% 6.10% 0.16% 0.16% 0.04% 0.04% Ferro 63.66% 63.66% 72.71% 81.37% 63.44% 63.44% 86.68% 86.68% Non-ferro 6.42% 6.42% 8.67% 2.84% 24.74% 24.74% 3.29% 3.29% MANUFACTURING Coating 4.95% 4.95% 0.00% 3.50% 10.46% 10.46% 0.62% 0.62% Electronics 0.54% 0.54% 1.63% 0.00% 0.01% 0.01% 0.00% 0.00% Misc. 8.79% 8.79% 9.24% 2.60% 1.14% 1.14% 7.19% 7.19% Total weight g 141, , ,330 1,003,755 2,667,000 3,067, , ,853 Sheetmetal Scrap 5% 5% 5% 5% 25% 5% 5% 5% DISTRIBUTION Volume of packaged final product in m Product Life years USE PHASE On-mode: Consumption per hour, cycle, setting, etc. kwh 2,000 5,000 3,031 12, , ,659 32,330 38,083 On-mode: No. Of hours, cycles, settings, etc. / year # Percentage of fugitive refrigerant 1% 1% 6% 9% 12% 12% 15% 15% Refrigerant in the product R134a R404A R404A R404A R134a R404A R404A R404A Refrigerant in the product g ,800 3, , ,000 11,100 11,100 Percentage of dumped refrigerant at end of 92% 92% 5% 73% 5% 5% 5% 5% life* DISPOSAL & Percentage of fugitive & dumped refrigerant 100% 100% 142% 163% 65% 65% 170% 170% RECYCLING Landfill (fraction products not recovered) 5% 5% 5% 5% 5% 5% 5% 5% Plastics: Re-use, Closed Loop Recycling 1% 1% 1% 1% 1% 1% 1% 1% Plastics: Materials Recycling 9% 9% 9% 9% 9% 9% 9% 9% Plastics: Thermal Recycling 90% 90% 90% 90% 90% 90% 90% 90% ECONOMIC & MARKET DATA Product Life years Annual sales mln. Units/year EU Stock mln. Units Product price Euro/unit 1,000 1,100 6,400 8,800 55,000 70,000 5,249 7,419 Installation/acquisition costs Euro/ unit ,760 5,500 7, Electricity rate Euro/kWh Repair & maintenance costs Euro/ unit ,500 7, Discount rate (interest minus inflation) 4.0% 4.0% 4.0% 4.0% 4.0% 4.0% 4.0% 4.0% Overall Improvement Ratio STOCK vs. NEW, Use Phase *According to stakeholders, the actual end-of-life refrigerant percentage dumped might reach up to 100%, not following the WEEE Directive. 96 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

391 4.10. BASE CASE ENVIRONMENTAL AND ECONOMIC IMPACT ASSESSMENT All the data presented in the section above where used to calculate environmental impacts. The results of the EcoReport impact assessment for each product group category are given below. The charts shown in this section correspond to the environmental impact generated during the life cycle of the product. Some impacts are represented in negative values in the charts representing the generation instead of the consumption, e.g. negative impact in energy represents energy production SERVICE CABINETS The impacts of the service cabinet Base Cases are presented below. Table 4-34: Environmental assessment results per HT PRODUCT from EcoReport for service cabinets Life Cycle phases --> PRODUCTION DISTRI- USE END-OF-LIFE* TOTAL Resources Use and Emissions Material Manuf. Total BUTION Disposal Recycl. Total Other Resources & Waste debet credit Total Energy (GER) MJ of which, electricity (in primary MJ) MJ Water (process) ltr Water (cooling) ltr Waste, non-haz./ landfill g Waste, hazardous/ incinerated g Emissions (Air) Greenhouse Gases in GWP100 kg CO2 eq Ozone Depletion, emissions mg R-11 eq. negligible Acidification, emissions g SO2 eq Volatile Organic Compounds (VOC) g Persistent Organic Pollutants (POP) ng i-teq Heavy Metals mg Ni eq PAHs mg Ni eq Particulate Matter (PM, dust) g Emissions (Water) Heavy Metals mg Hg/ Eutrophication g PO Persistent Organic Pollutants (POP) ng i-teq negligible Table 4-35: Environmental assessment results per LT PRODUCT from EcoReport for service cabinets Life Cycle phases --> PRODUCTION DISTRI- USE END-OF-LIFE* TOTAL Resources Use and Emissions Material Manuf. Total BUTION Disposal Recycl. Total Other Resources & Waste debet credit Total Energy (GER) MJ of which, electricity (in primary MJ) MJ Water (process) ltr Water (cooling) ltr Waste, non-haz./ landfill g Waste, hazardous/ incinerated g Emissions (Air) Greenhouse Gases in GWP100 kg CO2 eq Ozone Depletion, emissions mg R-11 eq. negligible Acidification, emissions g SO2 eq Volatile Organic Compounds (VOC) g Persistent Organic Pollutants (POP) ng i-teq Heavy Metals mg Ni eq PAHs mg Ni eq Particulate Matter (PM, dust) g Emissions (Water) Heavy Metals mg Hg/ Eutrophication g PO Persistent Organic Pollutants (POP) ng i-teq negligible Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 97

392 Impact indicator Table 4-36: Impact of the service cabinets per functional unit per year Impact per litre of capacity at +5 C per year Impact per litre of capacity at -18 C per year Total Energy (GER) (MJ) of which, electricity (in primary MJ) Use-phase electricity consumption (kwh) Water (process) (ltr) Waste, non-haz./ landfill (g) Waste, hazardous/ incinerated (g) Greenhouse Gases in GWP100 (kg CO2 eq.) Acidification, emissions (g SO2 eq.) Volatile Organic Compounds (VOC) (g) Persistent Organic Pollutants (POP) (ng i-teq) Heavy Metals (mg Ni eq.) PAHs (mg Ni eq.) Particulate Matter (PM, dust) (g) Heavy Metals (mg Hg/20) Eutrophication (g PO4) The environmental impacts of the blast cabinets at different life phases are represented below. Use phase and production material are the two phases with the biggest impact. Almost 100% of the electricity consumed during the life-time of this equipment is related to the use-phase, which in terms of Total Energy becomes around 92% for HT and 96% for LT. 100% 80% 60% 40% 20% 0% -20% End-of-life Use Distribution Manufacture Material production Figure 4-28: EcoReport results for HT service cabinets impacts per lifecycle stage 98 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

393 100% 80% 60% 40% 20% End-of-life Use Distribution 0% Manufacture -20% Material production Figure 4-29: EcoReport results for LT service cabinets impacts per lifecycle stage When taking into account the GER (Gross Energy Requirement) as a reference for the environmental impacts, the results show that the use phase is the most important (Figure 4-30). Besides, it is important to note that the end of-life phase provides GER with the thermal recovery of some parts of the service cabinet Material production Manufacture Distribution Use EOL HT LT Figure 4-30: GER related to each phase of the life cycle of service cabinet (MJ) Greenhouse Gases warming potential of service cabinet is mainly due to the use phase. The production of the electricity involves the combustion of fossil fuels and consequently emissions of carbon dioxide. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 99

394 HT LT Material production Manufacture Distribution Use EOL Figure 4-31: GWP related to each phase of the life cycle of service cabinet (kg CO2 eq.) The direct and indirect greenhouse gasses emissions comparison is shown below. The higher GWP for LT products is due to the use of R404A in place of R134a. HT GWP indirect GWP direct LT (kg CO2 eq.) Figure 4-32 Life cycle Total Equivalent Warming Impact (TEWI) of service cabinet Base Case, per product over lifetime Other impacts The process water used in the production phase is necessary in production of polyurethane used as an isolation of the service cabinet. Second process using significant amount of process water is production of steel. The water used during use phase is related to the electricity consumption. Concerning environmental impact on non-hazardous waste during the production phase, it is mainly due to materials as steel and copper. The use phase impacts are in similar proportions to electricity consumption. The high relative impact on hazardous waste during the End-of-Life phase is associated with incineration of plastics/pwb which are not being reused 100 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

395 or recycled. The use phase impact is connected to the electricity consumption. Emissions related to eutrophication mainly occur during production phase due to the coating. Heavy metals emissions to the air are due mainly to production of ferrite, and to water through the production of polyurethane used as an insulation of the service cabinet. The high amount of acidification emissions resulting from the use phase are correlated to electricity consumption. Relating to Persistent Organic Pollutants, impact during use phase again comes from the electricity consumption. The impact caused by the production phase is related to production of steel. Volatile Organic Compounds are mainly emitted during the use phase due to the electricity consumption. Distribution phase is the second source of emissions, because VOCs are usually related to so called mobile sources. Distribution phase is mainly responsible for emissions of Particulate Matter to the air. It is due to the transport. End-of-Life contribution is caused by incineration of plastics/pwb which are not being reused or recycled. Emissions of PAHs through production phase are related to the production of plastics (7-HI-PS) used as an inner cabinet lining. These materials are responsible for about half of the emissions Life Cycle Costs The EcoReport provides the following results for the LCC. For HT and LT, the electricity costs represent a major share of the LCC (61% HT and 78% LT) followed by the product purchase cost (36% HT and 20% LT). Table 4-37: Life Cycle Costs per product and total annual expenditure (2008) in the EU HT - LCC new product ( ) LT - LCC new product ( ) Total annual consumer expenditure in EU25 (mln ) EU Totals Product price Installation/ acquisition costs Electricity Repair & maintenance costs Total As presented in this section, the service cabinet consumes a large amount of electricity, produced in general by burning fossil fuel that emits CO 2 (carbon dioxide) into the atmosphere. By simply consuming energy over its life cycle, it contributes to climate change. A second environmental issue is the use of refrigerant, which also highly contributes to climate change. Poorly designed, badly maintained installations or Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 101

396 refrigeration units abandoned at the end of their life without recovering or recycling the refrigerant fluid can lead to emissions into the atmosphere. These emissions are known as direct effects. Regulations such as the WEEE directive seek to avoid this, but implementation has been described as variable (please see Task 3 discussion on end-of-life). Therefore is it assumed that significant amounts of refrigerant are released through leakage and at end-of-life. 102 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

397 Table 4-38: EU Total Impact of STOCK of Service Cabinet in 2008 TOTAL PRODUCTION DISTRIBUTION USE END-OF-LIFE Material Manuf. Total Disposal Recycl. Total Other Resources & Waste Total Energy (GER) PJ Total use-phase electricity consumption TWh Water (process) mln. m Water (cooling) mln. m Waste, non-haz./ landfill kt Waste, hazardous/ incinerated kt Emissions (Air) Greenhouse Gases in GWP100 mt CO2 eq Ozone Depletion, emissions t R-11 eq negligable Acidification, emissions kt SO2 eq Volatile Organic Compounds (VOC) kt Persistent Organic Pollutants (POP) g i-teq Heavy Metals ton Ni eq PAHs ton Ni eq Particulate Matter (PM, dust) kt Emissions (Water) Heavy Metals ton Hg/ Eutrophication kt PO Persistent Organic Pollutants (POP) g i-teq 0.00 negligable Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 103

398 The EU wide impact of such products in 2008 is estimated at a total energy consumption of approximately 123 PJ and GWP of 6 mt CO 2 eq Sensitivity analysis Impact Category A sensitivity analysis was performed to assess the change in environmental impacts when production material quantities are increased by +20% and +50%. Table 4-39: Production material sensitivity analysis change in total stock impacts units Base Case material +20% Base Case material +50% Absolute % increase over increase over Base Case Base Case Absolute increase over Base Case % increase over Base Case Total Energy (GER) PJ % % of which, electricity (in primary PJ) PJ % % Water (process) mln. m % % Water (cooling) mln. m % % Waste, non-haz./ landfill kt % % Waste, hazardous/ incinerated kt % % Greenhouse Gases in GWP100 mt CO2 eq % % Ozone Depletion, emissions t R-11 eq Acidification, emissions kt SO2 eq % % Volatile Organic Compounds (VOC) kt % % Persistent Organic Pollutants (POP) g i-teq % % Heavy Metals ton Ni eq % % PAHs ton Ni eq % % Particulate Matter (PM, dust) kt % % Heavy Metals ton Hg/ % % Eutrophication kt PO % % Persistent Organic Pollutants (POP) g i-teq Other Resources & Waste Total Energy (GER) of which, electricity (in primary MJ) Water (process) Water (cooling) Waste, non-haz./ landfill Waste, hazardous/ incinerated Greenhouse Gases in GWP100 Ozone Depletion, emissions Acidification, emissions Volatile Organic Compounds (VOC) Persistent Organic Pollutants (POP) Heavy Metals PAHs Table 4-40: Production material sensitivity analysis change in impacts across lifecycle phases units MJ MJ ltr ltr g g kg CO2 eq. mg R-11 eq. g SO2 eq. g ng i-teq mg Ni eq. mg Ni eq. Base Case material +20% Base Case material +50% Produ Distribu End Produ Distribu End of ction tion Use of life ction tion Use life % 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% % % -1.74% 0.04% 4.20% -0.07% -4.23% 0.11% % % -0.53% 0.00% 1.32% 0.00% -1.32% 0.00% % % -4.47% 0.00% % -9.99% -0.01% % % % -0.50% 0.00% 1.26% 0.00% -1.25% -0.01% % % -4.28% 0.18% 8.92% -0.07% -9.25% 0.40% % % -1.81% 1.74% 0.17% -0.03% -3.70% 3.56% % % -2.21% 0.00% 5.43% -0.12% -5.31% 0.01% % n.a. n.a % 3.23 % 3.70 % 2.44 % 3.19 % -0.03% -2.52% 0.06% 5.95% -0.07% -6.02% 0.14% -1.47% -2.19% 0.43% 7.51% -3.43% -5.09% 1.00% -0.03% -3.81% 0.14% 7.86% -0.06% -8.09% 0.29% -0.06% -2.51% 0.14% 5.04% -0.13% -5.19% 0.28% -0.71% -2.48% 0.00% 6.67% -1.48% -5.19% 0.00% 104 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

399 % -0.50% 3.04% 2.92% -8.66% -1.13% 6.88% Particulate Matter (PM, dust) g % % -1.71% 0.04% 3.41% -0.01% -3.49% 0.09% Heavy Metals mg Hg/20 % % -0.23% 0.01% 0.45% 0.00% -0.46% 0.02% Eutrophication g PO4 % Persistent Organic Pollutants (POP) ng i-teq n.a. n.a. Based on the sensitivity analysis for refrigerant charge, it is possible to conclude that this parameter do not have a significant impact over the lifetime of the product (see figure below). Base Case HT HT: charge +100% HT: leakage +100% Base Case LT GWP indirect GWP direct LT: charge +100% LT: leakage +100% (kg CO2 eq.) Figure 4-33: Sensitivity analysis Life cycle Total Equivalent Warming Impact (TEWI) of service cabinet Base Cases, per product over lifetime BLAST CABINETS The impacts of the blast cabinet Base Case are presented below. Table 4-41: Environmental assessment results per PRODUCT from EcoReport for blast cabinets Base Case Life Cycle phases --> PRODUCTION DISTRI- USE END-OF-LIFE* TOTAL Resources Use and Emissions Material Manuf. Total BUTION Disposal Recycl. Total Other Resources & Waste debet credit Total Energy (GER) MJ of which, electricity (in primary MJ) MJ Water (process) ltr Water (cooling) ltr aste, non-haz./ landfill g Waste, hazardous/ incinerated g Emissions (Air) Greenhouse Gases in GWP100 kg CO2 eq Ozone Depletion, emissions mg R-11 eq. negligible Acidification, emissions g SO2 eq Volatile Organic Compounds (VOC) g Persistent Organic Pollutants (POP) ng i-teq Heavy Metals mg Ni eq PAHs mg Ni eq Particulate Matter (PM, dust) g Emissions (Water) Heavy Metals mg Hg/ Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 105

400 Eutrophication g PO Persistent Organic Pollutants (POP) ng i-teq negligible Table 4-42: Impact of the blast cabinets per functional unit per year (considering weighted contribution of kg of foodstuff processed in one year=220 business day) Impact indicator Impact per kg of foodstuff at cycle temperature per year Total Energy (GER) (MJ) 2.06 of which, electricity (in primary MJ) 1.98 electricity (kwh) 0.19 Water (process) (Ltr) 0.17 Waste, non-haz./ landfill (g) 3.67 Waste, hazardous/ incinerated (g) 0.13 Greenhouse Gases in GWP100 (kg CO2 eq.) 0.20 Acidification, emissions (g SO2 eq.) 0.55 Volatile Organic Compounds (VOC) (g) 0.00 Persistent Organic Pollutants (POP) (ng i-teq) 0.02 Heavy Metals (mg Ni eq.) 0.09 PAHs (mg Ni eq.) 0.01 Particulate Matter (PM, dust) (g) 0.04 Heavy Metals (mg Hg/20) 0.05 Eutrophication (g PO4) % The environmental impacts of the blast cabinets at different life phases are represented in Figure Use phase and production material are the two phases with the biggest impact. About 99% of the electricity consumed during the lifetime of this equipment is related to the use-phase, which in terms of Total Energy becomes around 95%. 80% 60% 40% 20% 0% EOL Use Distribution Prod. Manuf. Prod. Material -20% Figure 4-34: EcoReport LCA analysis results for blast cabinets impacts per lifecycle stage When taking into account the GER (Gross Energy Requirement) as a reference for the environmental impacts, the results show that the use phase is the most 106 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

401 important. It is responsible of 95% of the GER required during the whole life cycle. The production phase is the second stage, representing around 4% of the GER over product lifetime. The distribution and end-of-life phase are negligible. Besides, it is important to note that the end of-life phase provides GER with the thermal recovery of some parts of the blast cabinet Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-35: GER related to each phase of the life cycle of blast cabinet (MJ) Greenhouse Gases warming of blast cabinets is mainly due to the end-of-life phase, closely followed by the use phase. The high percentage of dumped refrigerant contributes to this. The electricity production involves the combustion of fossil fuels and consequently emissions of carbon dioxide Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-36: GWP related to each phase of the life cycle of blast cabinet (kg CO2 eq.) The direct and indirect greenhouse gasses emissions comparison is shown below: Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 107

402 Figure 4-37: Life cycle Total Equivalent Warming Impact (TEWI) of blast cabinet Base Case, per product over lifetime Other impacts the process water used in the production phase is necessary in the production of steel as well as the polyurethane foam used to isolate the blast cabinet. The water used during use phase is related to the electricity consumption (see Annex). concerning the environmental impact of non-hazardous waste during the production phase, it is mainly due to materials as steel and copper. The use phase impacts are higher due to electricity consumption (see Annex). the high relative impact of hazardous waste during the End-of-Life phase is associated with incineration of plastics/pwb which are not being reused or recycled, and dumped refrigerant. The use phase impact is connected to the electricity consumption. In the production phase, emissions of hazardous waste are due to PWB included in the electronic parts (see Annex). the high amount of acidification emissions resulting from the use phase are correlated to electricity consumption. relating to Persistent Organic Pollutants, their impact during the use phase again comes from the electricity consumption. The impact caused by the production phase is related to production of ferrous metals. Volatile Organic Compounds are mainly emitted during the use phase due to the electricity consumption. The use phase is the largest source of emissions. heavy metal emissions to the air from the use phase are smaller to use phase electricity production, indicating that heavy metal emissions for this phase are associated with the electricity production. Emissions occurred during the production phase are related to production of stainless coil used in the housing of the cabinet. emissions of PAHs through the production phase are related to the production of ferrous metals. These materials are responsible for about half of the emissions. Use phase emissions are correlated to energy consumption. following the use phase, the distribution phase is mainly responsible for emissions of Particulate Matter to the air with the end-of-life phase. It is due to the transport. The end-of-life contribution is caused by incineration of plastics/pwbs which are not being reused or recycled, and dumped refrigerant. 108 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

403 emissions to water tackled by the EcoReport tool are heavy metals and eutrophication. Concerning emissions of heavy metals through the production phase, half of this impact is due to production of steel used in housing of the blast cabinet. Use phase emissions are again related to electricity consumption. emissions related to eutrophication mainly occur during the production phase due to polyurethane insulation foam and steel materials Life Cycle Costs The EcoReport provides the following results for the LCC. The electricity costs represent around half of the share of the product price. Table 4-43: Life Cycle Costs per product and Total annual expenditure (2008) in the EU-27 Blast Cabinet LCC new product total annual consumer expenditure in EU25 Item Product price 6,400 1,111 mln. Installation/ acquisition costs (if any) Fuel (gas, oil, wood) 0 0 mln. Electricity 2, mln. Water 0 0 mln. Aux. 1: None 0 0 mln. Aux. 2 :None 0 0 mln. Aux. 3: None 0 0 mln. Repair & maintenance costs mln. Total 9,512 1,705 mln EU Totals As presented in section above, the blast cabinet consumes a large amount of electricity, produced in general by burning fossil fuel that emits CO 2 (carbon dioxide) into the atmosphere. By the simple fact of consuming energy over its life cycle, it contributes to climate change. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 109

404 Table 4-44: EU Total Impact of STOCK of Blast Cabinet in 2008 Life Cycle phases --> PRODUCTION DISTRI- USE END-OF-LIFE* TOTAL Resources Use and Emissions Material Manuf. Total BUTION Disposal Recycl. Total Other Resources & Waste debet credit Total Energy (GER) PJ of which, electricity (in primary PJ) PJ Water (process) mln. m Water (cooling) mln. m Waste, non-haz./ landfill kt Waste, hazardous/ incinerated kt Emissions (Air) Greenhouse Gases in GWP100 mt CO2 eq Ozone Depletion, emissions t R-11 eq. negligible Acidification, emissions kt SO2 eq Volatile Organic Compounds (VOC) kt Persistent Organic Pollutants (POP) g i-teq Heavy Metals ton Ni eq PAHs ton Ni eq Particulate Matter (PM, dust) kt Emissions (Water) Heavy Metals ton Hg/ Eutrophication kt PO Persistent Organic Pollutants (POP) g i-teq negligible The EU wide impact of such products in 2008 is estimated to a total energy consumption of 116 PJ and to a GWP of 6 mt CO 2 eq Sensitivity analysis Impact Category A sensitivity analysis was performed to assess the change in environmental impacts when production material quantities are increased by +20% and +50%. Table 4-45: Production material sensitivity analysis change in total stock impacts units Base Case material +20% Base Case material +50% Absolute % increase over increase over Base Case Base Case Absolute increase over Base Case Total Energy (GER) PJ % % of which, electricity (in primary PJ) PJ % % Water (process) mln. m % % Water (cooling) mln. m % % Waste, non-haz./ landfill kt % % Waste, hazardous/ incinerated kt % % Greenhouse Gases in GWP100 mt CO2 eq % % Ozone Depletion, emissions t R-11 eq Acidification, emissions kt SO2 eq % % Volatile Organic Compounds (VOC) kt % % Persistent Organic Pollutants (POP) g i-teq % % Heavy Metals ton Ni eq % % PAHs ton Ni eq % % Particulate Matter (PM, dust) kt % % Heavy Metals ton Hg/ % % Eutrophication kt PO % % Persistent Organic Pollutants (POP) g i-teq % increase over Base Case 110 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

405 Table 4-46: Production material sensitivity analysis change in impacts across lifecycle phases Base Case material +20% Base Case material +50% units Produ ction Distribu tion Use End of life Produ ction Distribu tion Use End of life Other Resources & Waste 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% Total Energy (GER) MJ 0.62% -0.01% -0.62% 0.01% 1.53% -0.02% -1.53% 0.03% of which, electricity (in primary MJ) MJ 0.16% 0.00% -0.16% -0.01% 0.41% 0.00% -0.39% -0.02% Water (process) ltr 3.21% 0.00% -3.16% -0.05% 7.56% 0.00% -7.44% -0.13% Water (cooling) ltr 0.10% 0.00% -0.10% 0.00% 0.24% 0.00% -0.24% 0.00% Waste, non-haz./ landfill g 4.17% -0.02% -4.30% 0.16% 9.43% -0.06% -9.73% 0.36% Waste, hazardous/ incinerated g 1.05% -0.02% -3.96% 2.93% 2.23% -0.05% -8.43% 6.25% Greenhouse Gases in GWP100 kg CO2 eq. 0.45% -0.01% -0.20% -0.25% 1.12% -0.01% -0.49% -0.61% Ozone Depletion, emissions mg R-11 eq. n.a. n.a. Acidification, emissions g SO2 eq. 1.19% -0.02% -1.18% 0.00% 2.92% -0.04% -2.89% 0.01% Volatile Organic Compounds (VOC) g 2.17% -0.78% -1.51% 0.11% 5.22% -1.87% -3.62% 0.27% Persistent Organic Pollutants (POP) ng i-teq 4.34% -0.03% -4.47% 0.15% 9.66% -0.06% -9.95% 0.34% Heavy Metals mg Ni eq. 3.96% -0.08% -4.02% 0.14% 8.48% -0.17% -8.60% 0.29% PAHs mg Ni eq. 4.56% -0.48% -4.02% -0.07% % -1.05% -8.83% -0.15% Particulate Matter (PM, dust) g 1.70% -2.11% -2.38% 2.79% 3.79% -4.72% -5.33% 6.25% Heavy Metals mg Hg/ % -0.01% -3.33% 0.02% 6.94% -0.01% -6.98% 0.05% Eutrophication g PO4 0.70% 0.00% -0.71% 0.02% 1.41% -0.01% -1.43% 0.03% Persistent Organic Pollutants (POP) ng i-teq n.a. n.a. Based on the sensitivity analysis for refrigerant charge, it is possible to conclude that this parameter does have a significant impact over the lifetime of the product (see figure below). Therefore, alternative refrigerants with lower GWP should be considered. Base Case LT: charge +100% GWP indirect GWP direct LT: leakage +100% Figure 4-38: Sensitivity analysis Life cycle Total Equivalent Warming Impact (TEWI) of blast cabinet Base Case, per product over lifetime increasing in 50% and 100% refrigerant charge WALK-IN COLD ROOMS The impacts of the walk-in cold room Base Case are presented below. Table 4-47: Environmental assessment results per PRODUCT from EcoReport for walk-in cold rooms Life Cycle phases --> PRODUCTION DISTRI- USE END-OF-LIFE* TOTAL Resources Use and Emissions Material Manuf. Total BUTION Disposal Recycl. Total Other Resources & Waste debet credit Total Energy (GER) MJ of which, electricity (in primary MJ) MJ Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 111

406 Life Cycle phases --> PRODUCTION DISTRI- USE END-OF-LIFE* TOTAL Resources Use and Emissions Material Manuf. Total BUTION Disposal Recycl. Total Water (process) ltr Water (cooling) ltr Waste, non-haz./ landfill g Waste, hazardous/ incinerated g Emissions (Air) Greenhouse Gases in GWP100 kg CO2 eq Ozone Depletion, emissions mg R-11 eq. negligible Acidification, emissions g SO2 eq Volatile Organic Compounds (VOC) g Persistent Organic Pollutants (POP) ng i-teq Heavy Metals mg Ni eq PAHs mg Ni eq Particulate Matter (PM, dust) g Emissions (Water) Heavy Metals mg Hg/ Eutrophication g PO Persistent Organic Pollutants (POP) ng i-teq negligible Other Resources & Waste debet credit Table 4-48: Impact of the walk-in cold rooms per functional unit per year impact per m3 of storage Impact indicator volume at storage temperature Total Energy (GER) (MJ) of which, electricity (in primary MJ) Use-phase electricity consumption (kwh) Water (process) (ltr) Waste, non-haz./ landfill (g) Waste, hazardous/ incinerated (g) Greenhouse Gases in GWP100 (kg CO2 eq.) Acidification, emissions (g SO2 eq.) Volatile Organic Compounds (VOC) (g) 4.18 Persistent Organic Pollutants (POP) (ng i-teq) Heavy Metals (mg Ni eq.) PAHs (mg Ni eq.) Particulate Matter (PM, dust) (g) Heavy Metals (mg Hg/20) Eutrophication (g PO4) The environmental impacts of the blast cabinets at different life phases are represented below. Use phase and production material are the two phases with the biggest impact. The majority of the electricity consumed during the life-time of this equipment is related to the use-phase, which in terms of Total Energy becomes around 87%. 112 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

407 100% 80% 60% End-of-life 40% Use 20% Distribution 0% Manufacture -20% Production material Figure 4-39: EcoReport results for walk-in cold rooms impacts per lifecycle stage When taking into account the GER (Gross Energy Requirement) as a reference for the environmental impacts, the results show that the use phase is the most important during the whole life cycle. It is important to note that the end of-life phase provides GER with the thermal recovery of some parts of the walk-in cold room Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-40: GER related to each phase of the life cycle of walk-in cold room (MJ) Greenhouse Gases warming potential of service cabinet is mainly due to the use phase. The production of the electricity involves the combustion of fossil fuels and consequently emissions of carbon dioxide. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 113

408 Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-41: GWP related to each phase of the life cycle of walk-in cold room (kg CO2 eq.) The direct and indirect greenhouse gasses emissions comparison is shown below: TEWI (kg CO2 eq.) GWP indirect GWP direct Figure 4-42 Life cycle Total Equivalent Warming Impact (TEWI) of walk-in cold room Base Case, per product over lifetime Other impacts Extraction of material to produce coating and insulation has significant impacts, leading to almost 100% of eutrophication and release of heavy metals, and the majority of POPs and VOCs. Emissions related to eutrophication mainly occur during production phase due to coating made out of copper, nickel and chromium. The process water used in the production phase is necessary in production of production of steel. The water used during use phase is related to the electricity consumption. Concerning environmental impact on non-hazardous waste during the production phase, it is mainly due to materials as steel and copper. The use phase impacts are in similar proportions to electricity consumption. The high relative impact on hazardous waste during the End-of-Life phase is associated with incineration of plastics/pwb which are not being reused or recycled. The use phase impact is connected to the electricity consumption. 114 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

409 Greenhouse Gases warming potential of walk-in cold room is mainly due to the use phase. The production of the electricity involves the combustion of fossil fuels and consequently emissions of carbon dioxide. The high amount of acidification emissions resulting from the use phase are correlated to electricity consumption. Relating to Persistent Organic Pollutants, impact during use phase again comes from the electricity consumption. The impact caused by the production phase is related to production of coating with materials as cooper, nickel and chromium. Volatile Organic Compounds are mainly emitted during the use phase due to the electricity consumption. Distribution phase is the second source of emissions, because VOCs are usually related to so called mobile sources. Heavy metals emissions to the air from use phase are in similar proportion to use phase electricity production, indicating that HM emissions for this phase are associated with the electricity production. Emissions occurred during production phase are related to use of materials as chromium, nickel and copper in the shell of the walk-in cold room. Emissions of PAHs through production phase are related to the production of plastics (5-PS) used as an inner cabinet lining. These materials are responsible for more than half of the emissions. Distribution phase is mainly responsible for emissions of Particulate Matter to the air. It is due to the transport. End-of-Life contribution is caused by incineration of plastics/pwb which are not being reused or recycled. Use phase is related to energy consumption Life Cycle Costs The EcoReport provides the following results for the LCC. The electricity costs represent a major share of the LCC (51%) followed by the product purchase cost (38%). Table 4-49: Life Cycle Costs per product and Total annual expenditure (2008) in the EU Walk-in cold room Item LCC new product Product price mln. Installation/ acquisition costs (if any) mln. Fuel (gas, oil, wood) 0 0 mln. Electricity mln. Water 0 0 mln. Aux. 1: None 0 0 mln. Aux. 2 :None 0 0 mln. Aux. 3: None 0 0 mln. Repair & maintenance costs mln. Total mln. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 115

410 EU Totals As presented in this section, the walk-in cold room consumes a large amount of electricity, produced in general by burning fossil fuel that emits CO 2 (carbon dioxide) into the atmosphere. By the simple fact of consuming energy over its life cycle, it contributes to climate change. A second environmental issue is the use of refrigerant, which also highly contributes to climate change. 116 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

411 Table 4-50: EU Total Impact of STOCK of walk-in cold rooms TOTAL PRODUCTION DISTRIBUTION USE END-OF-LIFE Material Manuf. Total Disposal Recycl. Total Other Resources & Waste Total Energy (GER) PJ Total use-phase electricity consumption TWh Water (process) mln. m Water (cooling) mln. m Waste, non-haz./ landfill kt Waste, hazardous/ incinerated kt Emissions (Air) Greenhouse Gases in GWP100 mt CO2 eq Ozone Depletion, emissions t R-11 eq negligible Acidification, emissions kt SO2 eq Volatile Organic Compounds (VOC) kt Persistent Organic Pollutants (POP) g i-teq Heavy Metals ton Ni eq PAHs ton Ni eq Particulate Matter (PM, dust) kt Emissions (Water) 0.00 Heavy Metals ton Hg/ Eutrophication kt PO Persistent Organic Pollutants (POP) g i-teq 0.00 negligible Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 117

412 The EU wide impact of such products in 2008 is estimated to a total energy consumption of 218 PJ and to a GWP of 11 mt CO 2 eq Sensitivity analysis Impact Category A sensitivity analysis was performed to assess the change in environmental impacts when production material quantities are increased by +20% and +50%. Table 4-51: Production material sensitivity analysis change in total stock impacts units Base Case material +20% Base Case material +50% Absolute % increase over increase over Base Case Base Case Absolute increase over Base Case % increase over Base Case Total Energy (GER) PJ % % of which, electricity (in primary PJ) PJ % % Water (process) mln. m % % Water (cooling) mln. m % % Waste, non-haz./ landfill kt % % Waste, hazardous/ incinerated kt % % Greenhouse Gases in GWP100 mt CO2 eq % % Ozone Depletion, emissions t R-11 eq Acidification, emissions kt SO2 eq % % Volatile Organic Compounds (VOC) kt % % Persistent Organic Pollutants (POP) g i-teq % % Heavy Metals ton Ni eq % % PAHs ton Ni eq % % Particulate Matter (PM, dust) kt % % Heavy Metals ton Hg/ % % Eutrophication kt PO % % Persistent Organic Pollutants (POP) g i-teq Table 4-52: Production material sensitivity analysis change in impacts across lifecycle phases Base Case material +20% Base Case material +50% units Produ ction Distribu tion Use End of life Produ ction Distribu tion Use End of life Other Resources & Waste 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% Total Energy (GER) MJ 2.16% -0.03% -2.16% 0.03% 5.06% -0.08% -5.04% 0.06% of which, electricity (in primary MJ) MJ 1.49% 0.00% -1.49% 0.00% 3.56% 0.00% -3.56% 0.00% Water (process) ltr 4.47% 0.00% -4.46% 0.00% 9.99% 0.00% -9.98% 0.00% Water (cooling) ltr 0.51% 0.00% -0.51% 0.00% 1.27% 0.00% -1.27% 0.00% Waste, non-haz./ landfill g 4.56% -0.03% -4.65% 0.12% 9.44% -0.06% -9.64% 0.27% Waste, hazardous/ incinerated g 0.12% -0.02% -3.20% 3.10% 0.25% -0.04% -6.69% 6.48% 2.44% -0.04% -2.03% % -0.10% -4.72% - Greenhouse Gases in GWP100 kg CO2 eq. 0.36% 0.83% mg R-11 n.a. n.a. Ozone Depletion, emissions eq. Acidification, emissions g SO2 eq. 3.62% -0.04% -3.60% 0.02% 8.31% -0.09% -8.27% 0.06% Volatile Organic Compounds (VOC) g 4.34% -1.82% -2.76% 0.23% 8.73% -3.70% -5.61% 0.58% 4.56% -0.03% -4.52% % -0.05% -7.98% 0.04% Persistent Organic Pollutants (POP) ng i-teq 0.02% Heavy Metals mg Ni eq. 0.45% -0.01% -0.44% 0.00% 0.89% -0.02% -0.87% 0.00% PAHs mg Ni eq. 4.24% -0.90% -3.34% 0.00% 9.12% -1.93% -7.18% 0.00% Particulate Matter (PM, dust) g 1.69% -3.35% -0.44% 2.10% 3.80% -7.68% -1.01% 4.90% Heavy Metals mg Hg/ % 0.00% -1.56% 0.02% 3.15% -0.01% -3.18% 0.04% Eutrophication g PO4 0.12% 0.00% -0.12% 0.00% 0.24% 0.00% -0.25% 0.00% Persistent Organic Pollutants (POP) ng i-teq n.a. n.a. Based on the sensitivity analysis for refrigerant charge, it is possible to conclude that this parameter has a significant impact over the lifetime of the product (see figure below). 118 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

413 Base Case Charge +100% GWP indirect Leakage +100% GWP direct (kg CO2 eq.) Figure 4-43: Sensitivity analysis Life cycle Total Equivalent Warming Impact (TEWI) of walk-in cold room Base Case, per product over lifetime PROCESS CHILLER The impacts of the process chiller Base Cases are presented below. Table 4-53: Environmental assessment results per MT PRODUCT from EcoReport for process chiller Life Cycle phases --> PRODUCTION DISTRI- USE END-OF-LIFE* TOTAL Resources Use and Emissions Material Manuf. Total BUTION Disposal Recycl. Total Other Resources & Waste debet credit Total Energy (GER) MJ of which, electricity (in primary MJ) MJ Water (process) ltr Water (cooling) ltr Waste, non-haz./ landfill g aste, hazardous/ incinerated g Emissions (Air) Greenhouse Gases in GWP100 kg CO2 eq Ozone Depletion, emissions mg R-11 eq. negligible Acidification, emissions g SO2 eq Volatile Organic Compounds (VOC) g Persistent Organic Pollutants (POP) ng i-teq Heavy Metals mg Ni eq PAHs mg Ni eq Particulate Matter (PM, dust) g Emissions (Water) Heavy Metals mg Hg/ Eutrophication g PO Persistent Organic Pollutants (POP) ng i-teq negligible Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 119

414 Table 4-54: Environmental assessment results per LT PRODUCT from EcoReport for process chiller Life Cycle phases --> PRODUCTION DISTRI- USE END-OF-LIFE* TOTAL Resources Use and Emissions Material Manuf. Total BUTION Disposal Recycl. Total Other Resources & Waste debet credit Total Energy (GER) MJ of which, electricity (in primary MJ) MJ Water (process) ltr Water (cooling) ltr ####### Waste, non-haz./ landfill g Waste, hazardous/ incinerated g Emissions (Air) Greenhouse Gases in GWP100 kg CO2 eq Ozone Depletion, emissions mg R-11 eq. negligible Acidification, emissions g SO2 eq Volatile Organic Compounds (VOC) g Persistent Organic Pollutants (POP) ng i-teq Heavy Metals mg Ni eq PAHs mg Ni eq Particulate Matter (PM, dust) g Emissions (Water) Heavy Metals mg Hg/ Eutrophication g PO Persistent Organic Pollutants (POP) ng i-teq negligible Table 4-55: Impact of chillers per functional unit per year Impact indicator Impact per kw of capacity Impact per kw of capacity at -8 C per year at -25 C per year Total Energy (GER) (MJ) 14, ,676.0 of which, electricity (in primary MJ) 14, ,636.4 electricity (kwh) 1, ,965.4 Water (process) (ltr) ,384.5 Waste, non-haz./ landfill (g) 17, ,950.1 Waste, hazardous/ incinerated (g) Greenhouse Gases in GWP100 (kg CO2 eq.) Acidification, emissions (g SO2 eq.) 3, ,331.5 Volatile Organic Compounds (VOC) (g) Persistent Organic Pollutants (POP) (ng i-teq) Heavy Metals (mg Ni eq.) PAHs (mg Ni eq.) Particulate Matter (PM, dust) (g) Heavy Metals (mg Hg/20) Eutrophication (g PO4) The figure below describes the proportions of the impacts caused during the various lifecycle stages of the product. 120 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

415 100% 80% 60% 40% 20% 0% -20% End-of-life Use Distribution Manufacture Figure 4-44 EcoReport LCA analysis results for MT chillers impacts per lifecycle stage 100% 80% 60% 40% 20% 0% -20% End-of-life Use Distribution Manufacture Figure 4-45 EcoReport LCA analysis results for LT chillers impacts per lifecycle stage When taking into account the GER (Gross Energy Requirement) as a reference for the environmental impacts, the results show that the use phase is the most important. It is responsible of fewer than 100% of the GER required during the whole life cycle. The production phase is the second stage, representing around 0.3% of the GER over product lifetime. The distribution and end-of-life phase are negligible. Besides, it is important to note that the end of-life phase provides GER with the thermal recovery of some parts of the packaged process chiller. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 121

416 MT LT Material production Manufacture Distribution Use EOL Figure 4-46: GER related to each phase of the life cycle of chiller (MJ) Greenhouse Gases warming potential of chiller is mainly due to the use phase. The production of the electricity involves the combustion of fossil fuels and consequently emissions of carbon dioxide MT LT Material production Distribution EOL Figure 4-47: GWP related to each phase of the life cycle of chiller (kg CO2 eq.) The direct and indirect greenhouse gasses emissions comparison is shown below. The higher GWP for LT products is due to the use of R404A in place of R134a. 122 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

417 MT LT GWP indirect GWP direct Figure 4-48: Life cycle Total Equivalent Warming Impact (TEWI) of chillers, per product over lifetime Other impacts The process water used in the production phase is necessary in production mainly of steel elements included in chiller. The water used during use phase is related to the electricity consumption. Concerning environmental impact on non-hazardous waste during the production phase, it is mainly due to materials as steel and copper. The use phase impacts are in similar proportions to electricity consumption. The impact on hazardous waste during the use phase impact is connected to the electricity consumption. Other life phases are negligible. The high amount of acidification emissions resulting from the use phase are correlated to electricity consumption. Relating to Persistent Organic Pollutants, impact during use phase again comes from the electricity consumption. The impact caused by the production phase is related to production of ferrous metals. Volatile Organic Compounds are mainly emitted during the use phase due to the electricity consumption. Production phase emissions are related to the pre-coating coil material. Heavy metals emissions to the air from use phase are in similar proportion to use phase electricity production, indicating that HM emissions for this phase are associated with the electricity production. Emissions occurred during production phase are related to production of stainless coil. Emissions of PAHs through production phase are related to the production of ferrous metals. Use phase emissions are correlated to energy consumption. Following the use phase, the production phase is mainly responsible for emissions of Particulate Matter to the air (due to ferrous materials). Endof-Life contribution is caused by incineration of plastics/pwb which are not being reused or recycled. Emissions to water tackled by EcoReport tool are heavy metals and eutrophisation. Concerning emissions of heavy metals through production phase, half of this impact is due to production of steel and other ferrous metals. Use phase emissions are again related to electricity consumption. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 123

418 Emissions related to eutrophication mainly occur during production phase due to ferrous materials Life Cycle Costs The EcoReport provides the following results for the LCC. The electricity costs represent the biggest share of the LCC (around 89 %), followed by price of the product. Table 4-56: Life Cycle Costs per product and Total annual expenditure (2008) in the EU-27 MT LCC new product ( ) LT LCC new product ( ) Total annual consumer expenditure in EU25 (mln ) Product price 55,000 70, Installation/acquisition costs 5,500 7, Electricity 561, ,058 5,136 Repair and maintenance costs 4,077 5, Total 626, ,246 5, EU Totals As presented in section above, the chiller consumes a large amount of electricity, produced in general by burning fossil fuel that emits CO 2 (carbon dioxide) into the atmosphere. By the simple fact of consuming energy over its life cycle, it contributes to climate change. 124 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

419 Table 4-57: EU Total Impact of STOCK of process chillers in 2008 TOTAL PRODUCTION DISTRIBUTION USE END-OF-LIFE Material Manuf. Total Disposal Recycl. Total Other Resources & Waste Total Energy (GER) PJ of which, electricity TWh Water (process) mln. m Water (cooling) mln. m Waste, non-haz./ landfill kt Waste, hazardous/ incinerated kt Emissions (Air) Greenhouse Gases in GWP100 mt CO2 eq Ozone Depletion, emissions t R-11 eq. 0 negligable Acidification, emissions kt SO2 eq Volatile Organic Compounds (VOC) kt Persistent Organic Pollutants (POP) g i-teq Heavy Metals ton Ni eq PAHs ton Ni eq Particulate Matter (PM, dust) kt Emissions (Water) Heavy Metals ton Hg/ Eutrophication kt PO Persistent Organic Pollutants (POP) g i-teq 0 negligable Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 125

420 The EU wide impact of such products in 2008 is estimated to a total energy consumption of approximately 451 PJ and to a GWP of 21 mt CO 2 eq. MJ) (VOC) (POP) (POP) Sensitivity analysis Impact Category A sensitivity analysis was performed to assess the change in environmental impacts when production material quantities are increased by +20% and +50%. Table 4-58: Production material sensitivity analysis change in total stock impacts units Base Case material +20% Base Case material +50% Absolute % increase over increase over Base Case Base Case Absolute increase over Base Case % increase over Base Case Total Energy (GER) PJ % % of which, electricity (in primary PJ) PJ % % Water (process) mln. m % % Water (cooling) mln. m % % Waste, non-haz./ landfill kt % % Waste, hazardous/ incinerated kt % % Greenhouse Gases in GWP100 mt CO2 eq % % Ozone Depletion, emissions t R-11 eq Acidification, emissions kt SO2 eq % % Volatile Organic Compounds (VOC) kt % % Persistent Organic Pollutants (POP) g i-teq % % Heavy Metals ton Ni eq % % PAHs ton Ni eq % % Particulate Matter (PM, dust) kt % % Heavy Metals ton Hg/ % % Eutrophication kt PO % % Persistent Organic Pollutants (POP) g i-teq Table 4-59: Production material sensitivity analysis change in impacts across lifecycle phases Base Case material +20% Base Case material +50% Productio Distributio Distributio units Use End of life Production Use End of life Other Resources & Waste 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% Total Energy (GER) MJ 0.07% 0.00% -0.07% 0.00% 0.17% 0.00% -0.17% 0.00% of which, electricity (in primary MJ 0.02% 0.00% -0.02% 0.00% 0.04% 0.00% -0.04% 0.00% Water (process) ltr 0.21% 0.00% -0.21% 0.00% 0.53% 0.00% -0.53% 0.00% Water (cooling) ltr 0.02% 0.00% -0.02% 0.00% 0.04% 0.00% -0.04% 0.00% Waste, non-haz./ landfill g 1.09% 0.00% -1.14% 0.05% 2.68% 0.00% -2.80% 0.11% Waste, hazardous/ incinerated g 0.09% 0.00% -0.17% 0.08% 0.23% 0.00% -0.43% 0.20% Greenhouse Gases in GWP100 kg CO2 eq. 0.09% 0.00% -0.09% -0.01% 0.23% 0.00% -0.22% -0.01% mg R-11 Ozone Depletion, emissions eq. n.a. n.a. Acidification, emissions g SO2 eq. 0.11% 0.00% -0.11% 0.00% 0.28% 0.00% -0.28% 0.00% Volatile Organic Compounds g 0.44% -0.01% -0.46% 0.02% 1.10% -0.01% -1.14% 0.05% Persistent Organic Pollutants ng i-teq 1.72% 0.00% -1.77% 0.05% 4.17% 0.00% -4.29% 0.12% Heavy Metals mg Ni eq. 2.02% 0.00% -2.06% 0.05% 4.87% 0.00% -4.98% 0.11% PAHs mg Ni eq. 0.45% 0.00% -0.45% 0.00% 1.12% -0.01% -1.11% 0.00% Particulate Matter (PM, dust) g 1.09% -0.20% -1.49% 0.60% 2.66% -0.50% -3.61% 1.45% Heavy Metals mg Hg/ % 0.00% -1.98% 0.04% 4.70% 0.00% -4.78% 0.09% Eutrophication g PO4 3.52% 0.00% -3.56% 0.04% 7.42% 0.00% -7.51% 0.08% Persistent Organic Pollutants ng i-teq n.a. n.a. Based on the sensitivity analysis for refrigerant charge, it is possible to conclude that this parameter do not have a big impact over the lifetime of the product (see figure below). 126 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

421 Base Case MT MT: charge +50% MT: leakage +100% Base Case LT LT: charge +50% GWP indirect GWP direct LT: leakage +100% Figure 4-49: Sensitivity analysis Life cycle Total Equivalent Warming Impact (TEWI) of chiller Base Case, per product over lifetime increasing in 50% and 100% refrigerant charge REMOTE CONDENSING UNIT The impacts of the remote condensing unit Base Cases are presented below. Table 4-60: Environmental assessment results per MT PRODUCT from EcoReport for remote condensing unit Life Cycle phases --> PRODUCTION DISTRIBUTION USE EOL Other Resources & Waste Prod. Material Prod. Manuf. Total Distribution Use Disposal Recycl. EOL TOTAL Total Energy (GER) MJ 5,253 1,778 7, ,715, ,724,153 of which, electricity (in primary MJ) MJ 362 1,058 1, ,715, ,717,191 electricity (in kwh) kwh , ,780 Water (process) ltr 1, , , ,125 Water (cooling) ltr , ,242, ,243,299 Waste, non-haz./ landfill g 274,686 6, , ,151,574 8, ,468 3,441,401 Waste, hazardous/ incinerated g ,579 2, ,752 65,367 Emissions (Air) Greenhouse Gases in GWP100 kg CO2 eq ,519 72, , ,074 Ozone Depletion, emissions mg R-11 eq. negligible Acidification, emissions g SO2 eq. 2, , , ,039 Volatile Organic Compounds (VOC) g , ,058 Persistent Organic Pollutants (POP) ng i-teq 3, , , ,135 Heavy Metals mg Ni eq. 1, , , ,352 PAHs mg Ni eq , ,576 Particulate Matter (PM, dust) g ,382 14, ,763 Emissions (Water) Heavy Metals mg Hg/ , ,963 Eutrophication g PO Persistent Organic Pollutants (POP) ng i-teq negligible Table 4-61: Environmental assessment results per LT PRODUCT from EcoReport for remote condensing unit Life Cycle phases --> PRODUCTION DISTRIBUTION USE EOL Other Resources & Waste Prod. Material Prod. Manuf. Total Distribution Use Disposal Recycl. EOL TOTAL Total Energy (GER) MJ 6,304 2,133 8, ,199, ,209,050 of which, electricity (in primary MJ) MJ 435 1,270 1, ,199, ,200,706 electricity (in kwh) kwh , ,829 Water (process) ltr 1, , , ,555 Water (cooling) ltr , ,530, ,532,164 Waste, non-haz./ landfill g 329,623 7, , ,712,411 10, ,162 4,060,194 Waste, hazardous/ incinerated g ,714 3, ,303 77,059 Emissions (Air) Greenhouse Gases in GWP100 kg CO2 eq ,608 72, , ,279 Ozone Depletion, emissions mg R-11 eq. negligible Acidification, emissions g SO2 eq. 2, , , ,014 Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 127

422 Volatile Organic Compounds (VOC) g , ,248 Persistent Organic Pollutants (POP) ng i-teq 3, , , ,969 Heavy Metals mg Ni eq. 1, , , ,994 PAHs mg Ni eq , ,573 Particulate Matter (PM, dust) g ,859 17,601 1, ,028 22,186 Emissions (Water) Heavy Metals mg Hg/ , ,170 Eutrophication g PO Persistent Organic Pollutants (POP) ng i-teq negligible Table 4-62: Impact of remote condensing units per functional unit per year Impact indicator Impact per kw cooling Impact per kw cooling capacity per year for MT capacity per year for LT Total Energy (GER) 47,294 69,161 of which, electricity (in primary MJ) 3,162 4,624 electricity (in kwh) 59,747 87,504 Water (process) 1,135 1,661 Water (cooling) 3,317 4,575 Waste, non-haz./ landfill 12,188 17,824 Waste, hazardous/ incinerated Greenhouse Gases in GWP Ozone Depletion, emissions 839 1,228 Acidification, emissions Volatile Organic Compounds (VOC) Persistent Organic Pollutants (POP) Heavy Metals 2 3 PAHs 47,294 69,161 Particulate Matter (PM, dust) 3,162 4,624 Heavy Metals 59,747 87,504 Eutrophication 1,135 1,661 Persistent Organic Pollutants (POP) 3,317 4,575 When taking into account the GER (Gross Energy Requirement) as a reference for the environmental impacts, the results show that the use phase is the most important. It is responsible of 99.5% of the GER required during the whole life cycle. The production phase is the second stage, representing 0.4%. The distribution and end-of-life phase are negligible. The figure below describes the proportions of the impacts caused during the various lifecycle stages of the product. 128 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

423 Figure 4-50 EcoReport LCA analysis results for MT remote condensing units Figure 4-51 EcoReport LCA analysis results for LT remote condensing units Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 129

424 Figure 4-52: GER related to each phase of the life cycle of condensing unit (MJ) The process water used in the production and manufacturing phase is necessary in production mainly of ferrous metals included in condensing unit. The water used during use phase is related to the electricity consumption. Concerning environmental impact on non-hazardous waste during the production phase, it is mainly due to materials as steel and copper. The use phase impacts are in similar proportions to electricity consumption. The impact on hazardous waste during the use phase impact is connected to the electricity consumption. The End-of-Life emissions are related to incineration of plastics Greenhouse Gases warming potential of condensing unit is mainly due to the use phase. The production of the electricity involves the combustion of fossil fuels and consequently emissions of carbon dioxide. Figure 4-53: GWP related to each phase of the life cycle of condensing unit (kg CO2 eq.) 130 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

425 The direct and indirect greenhouse gasses emissions comparison is shown below. The refrigerant used is R404A, with a high GWP value, and the estimated leakage is 15% per year and 50% at the end of-life. A change to a low GWP refrigerant and leakage reduction would drive to a lower direct environmental impact. MT GWP indirect GWP direct LT Figure 4-54: Life cycle Total Equivalent Warming Impact (TEWI) of remote condening unit Base Case, per product over lifetime Other impacts The high amount of acidification emissions resulting from the use phase are correlated to electricity consumption. Relating to Persistent Organic Pollutants, impact during use phase again comes from the electricity consumption. The impact caused by the production phase is related to production of ferrous metals. Volatile Organic Compounds are mainly emitted during the use phase due to the electricity consumption. Production phase emissions are related to the pre-coating coil material and distribution phase is correlated to so called mobile sources. Heavy metals emissions to the air from use phase are in similar proportion to use phase electricity production, indicating that HM emissions for this phase are associated with the electricity production. Emissions occurred during production phase are related to production of steel used for chassis of appliance. Emissions of PAHs through production phase are related to the production of ferrous metals. Use phase emissions are correlated to energy consumption. Following the use phase, the distribution phase is mainly responsible for emissions of Particulate Matter to the air. End-of-Life contribution is caused by incineration of plastics which are not being reused or recycled. Emissions to water tackled by EcoReport tool are heavy metals and eutrophisation. Concerning emissions of heavy metals through production phase, this impact is due to production of steel and other ferrous metals. Use phase emissions are again related to electricity consumption. Emissions related to eutrophication occurring during production phase are due to ferrous materials production. However, use phase is dominant part. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 131

426 Life Cycle Costs The EcoReport provides the following results for the LCC. The electricity costs represent the biggest share of the LCC (84 % of the total annual consumer expenditure), followed by price of the product (13%). Table 4-63: Life Cycle Costs per product and Total annual expenditure (2008) in the EU-27 MT-LCC new product ( ) LT-LCC new product ( ) total annual consumer expenditure in EU25 (mln. ) Product price 5,249 7,419 3,238 Installation/ acquisition costs (if any) Electricity 26,121 30,768 20,357 Repair & maintenance costs Total 32,336 39,554 24, EU Totals As presented in section above, the condensing unit consumes a large amount of electricity, produced in general by burning fossil fuel that emits CO 2 (carbon dioxide) into the atmosphere. By the simple fact of consuming energy over its life cycle, it contributes to climate change. 132 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

427 Table 4-64: EU Total Impact of STOCK of Remote Condensing Units in 2008 TOTAL PRODUCTION DISTRIBUTION USE END-OF-LIFE Material Manuf. Total Disposal Recycl. Total Other Resources & Waste Total Energy (GER) PJ 1, , Water (process) mln. m Water (cooling) mln. m3 4, , Waste, nonhaz./ landfill kt 2, , Waste, hazardous/ kt incinerated Emissions (Air) Greenhouse Gases in mt CO2 eq GWP100 Ozone Depletion, t R-11 eq negligable emissions Acidification, emissions kt SO2 eq Volatile Organic Compounds kt (VOC) Persistent Organic Pollutants g i-teq (POP) Heavy Metals ton Ni eq PAHs ton Ni eq Particulate Matter (PM, kt dust) Emissions (Water) Heavy Metals ton Hg/ Eutrophication kt PO Persistent Organic Pollutants (POP) g i-teq 0.00 negligable The EU wide impact of such products in 2008 is estimated to a total energy consumption of approximately 989 PJ and to a GWP of 60 mt CO2 eq. Europ Proposal for Preparatory Study for Eco-de ENTR Lot 1: Refrigerating and f

428 Sensitivity analysis Impact Category A sensitivity analysis was performed to assess the change in environmental impacts when production material quantities are increased by +20% and +50%. Table 4-65: Production material sensitivity analysis change in total stock impacts units Base Case material +20% Base Case material +50% Absolute increase over Base Case % increase over Base Case Absolute increase over Base Case % increase over Base Case Total Energy (GER) PJ % % of which, electricity (in primary PJ) PJ % % Water (process) mln. m % % Water (cooling) mln. m % % Waste, non-haz./ landfill kt % % Waste, hazardous/ incinerated kt % % Greenhouse Gases in GWP100 mt CO2 eq % % Ozone Depletion, emissions t R-11 eq Acidification, emissions kt SO2 eq % % Volatile Organic Compounds (VOC) kt % % Persistent Organic Pollutants (POP) g i-teq % % Heavy Metals ton Ni eq % % PAHs ton Ni eq % % Particulate Matter (PM, dust) kt % % Heavy Metals ton Hg/ % % Eutrophication kt PO % % Persistent Organic Pollutants (POP) g i-teq Table 4-66: Production material sensitivity analysis change in impacts across lifecycle phases Base Case material +20% Base Case material +50% units Product Distribu End Product Distribu End of Use Use ion tion of life ion tion life Other Resources & Waste 0.00% 0.00% 0.00% 0.00 % 0.00% 0.00% 0.00% 0.00% Total Energy (GER) MJ 0.09% 0.01% -0.10% 0.01 % 0.22% 0.01% -0.24% 0.01% of which, electricity (in primary MJ) MJ 0.02% 0.00% -0.02% 0.00 % 0.04% 0.00% -0.04% 0.00% Water (process) ltr 0.20% 0.00% -0.19% 0.00 % 0.48% 0.00% -0.48% 0.00% Water (cooling) ltr 0.01% 0.00% -0.01% 0.00 % 0.01% 0.00% -0.01% 0.00% Waste, non-haz./ landfill g 2.20% 0.00% -2.27% 0.07 % 5.29% 0.00% -5.45% 0.16% Waste, hazardous/ incinerated g 0.01% 0.00% -1.29% 1.27 % 0.03% 0.00% -3.14% 3.10% Greenhouse Gases in GWP100 kg CO2 eq. 0.08% 0.01% -0.05% % 0.01% -0.13% -0.08% % Ozone Depletion, emissions mg R-11 eq. n.a. n.a. Acidification, emissions g SO2 eq. 0.12% 0.01% -0.13% 0.00 % 0.30% 0.01% -0.31% 0.01% Volatile Organic Compounds (VOC) g 0.55% 0.35% -0.96% % 0.32% -1.86% 0.16% 134 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

429 Base Case material +20% Base Case material +50% units Product Distribu End Product Distribu End of Use Use ion tion of life ion tion life % Persistent Organic Pollutants (POP) ng i-teq 3.39% 0.00% -3.46% 0.06 % 7.94% 0.00% -8.08% 0.14% Heavy Metals mg Ni eq. 0.98% 0.01% -1.10% 0.12 % 2.40% 0.01% -2.70% 0.29% PAHs mg Ni eq. 1.04% 0.14% -1.18% 0.00 % 2.58% 0.12% -2.69% 0.00% Particulate Matter (PM, dust) g 0.63% 1.92% -3.48% 0.93 % 1.72% 1.23% -5.49% 2.53% Heavy Metals mg Hg/ % 0.00% -0.79% 0.10 % 1.71% 0.00% -1.95% 0.24% Eutrophication g PO4 3.36% 0.00% -3.94% 0.58 % 7.54% 0.00% -8.89% 1.35% Persistent Organic Pollutants (POP) ng i-teq n.a. n.a. Based on the sensitivity analysis for refrigerant charge, it is possible to conclude that this parameter has a significant impact over the lifetime of the product (see figure below). Therefore, refrigerant charge reduction, refrigerant leakage prevention and the use of low GWP refrigerants would lower the direct environmental impact of remote condensing units. Base Case MT MT: charge +100% MT: leakage +100% Base Case LT GWP indirect GWP direct LT: charge +100% LT: leakage +100% (kg CO2 eq.) Figure 4-55 Sensitivity analysis Life cycle Total Equivalent Warming Impact (TEWI) of remote condensing unit Base Case, per product over lifetime increasing in 100% refrigerant charge and leakage rates Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 135

430 4.11. SUMMARY OF ENVIRONMENTAL IMPACTS Impact indicator The following table describes relevant eco-design indicators for the environmental impacts across the range of products covered in the scope of ENTR Lot 1. Table 4-67: Eco-design indicators for ENTR Lot 1 product groups per functional unit per year of life Unit Service cabinets HT Impact per litre net volume at +5 C Service cabinets LT Impact per litre net volume at -18 C Blast cabinets Impact per kg of foodstuff (referred to material proposed by NF AC D ) Walk-in cold rooms Impact per m 3 of net volume at +2 C Chillers MT Impact per kw cooling capacity to reach -10 C at +30 C /+35 C cond. inlet temperature Chillers LT Impact per kw cooling capacity to reach -18 C at +30 C/ +35 C cond. inlet temperature Remote condensing units MT Impact per kw cooling capacity at - 10 C evap. temp; +32 C ambient temp. Remote condensing units LT Impact per kw cooling capacity at - 10 C evap. temp; +32 C ambient temp. Total Energy (GER) MJ , , , ,294 69,161 of which, electricity (in MJ , , , ,162 4,624 primary MJ) electricity (in kwh) kwh ,747 87,504 Water (process) ltr , ,135 1,661 Water (cooling) ltr , , , ,317 4,575 Waste, nonhaz./ landfill g , , , ,188 17,824 Waste, hazardous/ g incinerated Greenhouse Gases in GWP100 kg CO2 eq Ozone Depletion, emissions Acidification, emissions Volatile Organic Compounds (VOC) Persistent Organic Pollutants (POP) mg R- 11 eq. g SO2 eq , , , , g ng i- Teq Heavy Metals mg Ni eq , PAHs mg Ni eq ,294 69,161 Particulate Matter (PM, g ,162 4,624 dust) Heavy Metals mg Hg/ ,747 87,504 Eutrophication g PO ,135 1,661 Persistent Organic ng i- Pollutants Teq ,317 4,575 (POP) 136 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

431 4.12. ECO-DESIGN INDICATORS The following table proposes some potential eco-design indicators that might be used by designers to understand and manage the environmental impacts of the products they design. Environmental impact Consumption of energy Consumption of material Consumption of other resources such as fresh water Emission to air, water and soil Physical effects such as noise Generation of waste materials Possibilities for reuse, recycling and recovery of material and/or energy Table 4-68: Potential eco-design indicators for designers Cause of impact Significant electricity consumption in all the products Use of metals in production phase (mainly ferrous metals) and plastics (mainly PUR) Use of cardboard for the packaging Water or other resources used in production processes (relevant share of the life cycle only for service cabinets and WICR) and for electricity production Manufacture and use Refrigerant leakage Compressor and/or fans Disposal Significant environmental impact (waste, resource use) if no reuse, recycling and recovery Potential eco-design indicator TEC, AEC, consumption per cycle, consumption per functional unit % of recycled content in metal parts Optimisation of the weight with substitute materials Ration of the volume of the packaged product with the volume of the product % of the recycled content in the packaging (cardboard and paper) Extension of the lifetime and/or the warranty Strong repair practices Collecting equipment at the EoL to ensure proper treatment and recycling The consumption of water (or other resources) in the production phase is mainly due to the extraction and production of ferrous metals (mostly the stainless steel). Producers of ferrous metals can developed a EMAS scheme (or equivalent) to monitor and manage their water consumption Reduction of amount of material used during manufacture (see consumption of material) % recovered refrigerant at EoL Strong repair practices to avoid leakages For machines under the machinery directive (2006/42/EC) noise is related to potential damage of the user; acoustic pressure [dba] % of product and/or refrigerant reused or recycled Full compliance with WEEE and RoHS Directives, when relevant, and targets set for the appropriate categories Possibility to use the heat removed from the equipment to heat up the building % of product and/or refrigerant reused or recycled energy recovery (MJ) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 137

432 4.13. CONCLUSIONS There is a great diversity in the type of refrigeration products covered in ENTR Lot 1, with different functionalities but often similar components used in the products. This report draws together information collected to this point, and its purpose is to provide an understanding of the assessment methodology (through a full analysis of the walk-in cold room Base Case), to provide a description of the data gathered to date for comment and feedback, and, importantly, to highlight data gaps. The technical analysis has described how there are significant potential savings achievable through the use of new technologies, but also highlights many other factors that can affect product performance. The EcoReport analysis shows that for all product groups, the use phase is the highest contributor to the total environmental impacts over the whole life span of the products due to energy consumption. The production phase is the second highest contributor due to manufacture of the products housing, which is responsible of most of the environmental impact through eutrophication and heavy metals released to air and water. The comparison between direct GWP emissions due to the refrigerant and indirect emissions due to electricity consumption shows that the contribution of the refrigerant to these is high in all the products under the scope. The use of low-gwp refrigerants, the reduction of the refrigerant charge and leakage rates would drive a reduction of the direct environmental impacts. The Base Cases will serve as a point of reference when evaluating the improvement potential (in Task 6) of various improvement options explored in Task 5. As most of the environmental impacts are expected to be caused by energy consumption during the use phase (as is the case for the plug-in walk-in cold room Base Case), the analysis of the improvement potential in Task 6 will primarily focus on technologies that reduce power consumption and improve energy efficiency, but will also consider refrigerant options due to the potential to decrease GWP. 138 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

433 ANNEXES Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 139

434 This page is left intentionally blank 140 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

435 ANNEX 4-1: Sub Base Case technical specifications SERVICE CABINETS Table 4-69: Characteristics of the service cabinet Sub Base Cases Product characteristics Sub Base Case HT Sub Base Case LT Product type/model/design: Vertical, 1-door Vertical, 1-door Location of condensing unit: Integral (plug-in) Integral (plug-in) Climate class: 4 4 M-package temperature class: M1 L1 Test standard: EN 441 EN 441 Internal cold storage temperature [ C]: +5 C -18 C Internal cold storage temperature range(s) ( C): +2 to +12 C -5 to -25 C Air-on temperature (ambient +30 C +30 C temperature) [ C]: Net internal volume [litres] 109 : Product use pattern [hours/year]: Functional unit: Litre of net volume at +5 C Litre of net volume at -18 C Power input [kw]: N.A. Cooling capacity [kw]: 0.35 N.A. COP: 1.11 N.A. AEC [kwh/year]: 2,000 5,000 TEC [kwh/48hrs]: EEI [kwh/48hrs/ m3]: Performance [kwh/litre net volume at storage temperature/year]: Price (ex VAT) [ ]: 1,000 1,100 Lifetime [years]: Refrigerant: R134a R404A Refrigerant charge [g]: Refrigerant leakage [% per 1% 1% annum]: Defrost type [natural/electric/hot gas/cool gas]: Natural Electric Defrost control (if applicable) [timed/off-cycle/on-demand]: Off-cycle Off-cycle Anti-condensation (if applicable): None None Expansion valve type: Capillary tube Capillary tube Other features not covered above: - - Weight of product [kg]: Calculated according to EN 441 method. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 141

436 Product characteristics Sub Base Case HT Sub Base Case LT External height [m] : External width [m] : External depth [m] : Gross total (shipping) volume [m3] : 1,211 1,211 Number of compressors: 1 1 Type of compressor: Hermetic reciprocating Hermetic reciprocating Power of compressor [W]: 195 N.A. Capacity of compressor [W]: 320 N.A. Weight of compressor [kg]: 10 N.A. Compressor motor control [none/two-speed/vsd]: None None Evaporator heat exchanger type and material: Fin and tube Fin and tube Evaporator face area [cm²]: 240 N.A. Evaporator fan motor type: Shaded pole axial Shaded pole axial Evaporator fan motor power [W]: 5 5 Evaporator fan motor control [none/two-speed/vsd]: None None Weight of evaporator module [kg]: 1 1 Condenser cooling: Air-cooled Air-cooled Condenser heat exchanger type and material: Fin and tube Fin and tube Condenser face area [cm²]: N.A. N.A. Condenser fan motor type: Shaded pole axial Shaded pole axial Condenser fan motor power [W]: 10 N.A. Condenser fan motor control [none/two-speed/vsd]: None None Weight of condenser module [kg]: 1.5 N.A. Number of doors: 1 1 Insulation type: Polyurethane Polyurethane Insulation thickness [mm]: Foaming agent: Cyclo-Pentan / Isopentane Cyclo-Pentan / Isopentane Lighting type [incandescent/fluorescent/led]: Incendescent Incendescent Lighting power [W]: Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

437 4.15. BLAST CABINETS Table 4-70: Characteristic of the blast cabinet Sub Base Case Product characteristic Sub-Base Case Product type/model/design: Vertical Location of condensing unit: Integrated Capacity [kg]: 20 Maximum number of trays (GN 1/1): 5 Cooling cycle*: chilling from +70 C to +3 C in 90 minutes Electricity consumption [kwh/cycle]: 2 Product use pattern [cycles/year]: 2 cycles per day, 220 days per year Condensing unit function [hours/day]: 3 Product use pattern [hours/year]: kg of foodstuff (referred to material proposed by NF AC D ) chilling from Functional unit: +70 C to +3 C in 90 minutes Power input [kw]: 1.2 Cooling capacity [kw]: 0.83 AEC [kwh/year]: 880 Performance [kwh/kg of foodstuff (referred to material proposed by NF AC D ) chilling from +70 C to +3 C in 90 minutes/year]: Performance [kwh/kg of foodstuff (referred to material proposed by NF AC D ) freezing from +70 C to +3 C in 90 minutes/cycle]: Price (ex VAT) [ ]: 3,400 Lifetime [years]: 8.5 Refrigerant: R404A Refrigerant charge [kg]: 0.8 Refrigerant leakage [% per annum]: 5 Defrost type [natural/electric/hot gas/cool gas]: not included Defrost control (if applicable) [timed/offcycle/on-demand]: not included Door frame heater wire: not included Defrost load [amps]: - Anti-condensation (if applicable): not included Expansion valve type: Thermostatic expansion valve Weight of product [kg]: 120 External height [cm]: 850 External width [cm]: 800 External depth [cm]: 700 Net volume [m³]: 52 Gross total (shipping) volume [m3] : 0.81 Shipping weight [kg]: 150 Number of compressors: 1 Type of compressor: Power of compressor [W]: 969 Capacity of compressor [W]: 813 Hermetic reciprocating Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 143

438 Product characteristic Sub-Base Case Weight of compressor [kg]: 12.5 Compressor motor control [none/twospeed/vsd]: N.A. Evaporator heat exchanger type and material: Fined tube / aluminum copper Evaporator face area [cm²]: N.A. Evaporator fan motor type: Axial Evaporator fan motor power [W]: 160 Evaporator fan motor control [none/twospeed/vsd]: N.A. Weight of evaporator module [kg]: N.A. Condenser cooling: Air-cooled Condenser heat exchanger type and material: Fined tube / aluminum copper Condenser face area [cm²]: N.A. Condenser fan motor type: Axial Condenser fan motor power [W]: 60 Condenser fan motor control [none/twospeed/vsd]: N.A. Weight of condenser module [kg]: 2.5 Number of doors: 1 Door material : Stainless steel Insulation type: Polyurethane Insulation thickness [mm]: 55 Foaming agent: Water Self closing door, evaporation temperature control with thermostat valve, inner door Other features: stop, temp. detector probe *As commonly referred to in brochures. Only for comparison purposes 144 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

439 4.16. WALK-IN COLD ROOMS Table 4-71: Estimated characteristics of the walk-in cold room Base Case Product characteristics Weighted Base Case Product type/model/design: Factory-built Location of condensing unit: Packaged refrigeration unit Test standard: - Internal cold storage temperature [ C]: +2 C Internal cold storage temperature range(s) +1 C to +4 C ( C): Air-on temperature (ambient temperature) +32 C [ C]: Net internal volume [m³]: 25 Condensing unit function [hours/day]: 16hrs to 18hrs condensing unit (on/off) Product use pattern [hours/year]: 8,760 Functional unit: m³ of net internal volume at +2 C Power input [kw]: 2 Cooling capacity [kw]: 2.1 COP: 1.5 AEC* [kwh/year]: 10,570 TEC [kw/48hrs]: 58 Performance [kwh/m³ at +2 C/year]: 423 Price (ex VAT) [ ]: 8,800 Lifetime [years]: 10 Refrigerant: R404A Refrigerant charge [g]: 2,400 Refrigerant leakage [% per annum]: 5 Defrost type [natural/electric/hot gas/cool N.A. gas]: Defrost control (if applicable) [timed/offcycle/on-demand]: N.A. Anti-condensation (if applicable): N.A. Expansion valve type: N.A. Other features not covered above: - Weight of product [kg]: 1000 External height [cm] : 232 External width [cm] : 362 External depth [cm] : 342 Gross total (shipping) volume [m3] : 29 Number of compressors: 1 Type of compressor: Hermetic reciprocating Power of compressor [W]: N.A. Capacity of compressor [W]: N.A. Weight of compressor [kg]: N.A. Compressor motor control [none/twospeed/vsd]: Not applicable Evaporator heat exchanger type and material: Fin and tube Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 145

440 Product characteristics Weighted Base Case Evaporator face area [cm²]: N.A. Evaporator fan motor type: Shaded pole axial Evaporator fan motor power [W]: N.A. Evaporator fan motor control [none/twospeed/vsd]: None Weight of evaporator module [kg]: N.A. Condenser cooling: Air-cooled Condenser heat exchanger type and material: Fin and tube Condenser face area [cm²]: N.A. Condenser fan motor type: Shaded pole axial Condenser fan motor power [W]: N.A. Condenser fan motor control [none/twospeed/vsd]: None Weight of condenser module [kg]: N.A. Number of doors: 1 Door type Hinged; 800x1900mm Strip door curtains Included Insulation type: Polyurethane; cam-locked Insulation thickness [mm]: 100 Foaming agent: Cyclo-Pentan/Isopentane Lighting type [incandescent/fluorescent/led]: Incendescent Lighting power [W]: 80 *Due to no current measurement standard for walk-in cold rooms and no information provided on real electricity consumption, AEC for this 25m 3 chiller walk-in cold room is calculated from the weighted Base Case, assuming that the market proportion of chiller to freezer if 70% to 30%, and that a freezer of 25m 3 AEC would be 2 times that of a chiller room. 146 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

441 4.17. PROCESS CHILLERS Table 4-72: Characteristic of the packaged process chiller 110 Sub Base Cases Product characteristics Sub Base Case MT Sub Base Case LT Product type/model/design: Packaged Packaged Location of condensing unit: Integral (packaged) Integral (packaged) Evaporator output temperature [ C]: Water on [ C]: Air-on temperature (ambient temperature) [ C]: Water solution [%]: Ethylene glycol 35% Ethylene glycol 35% Condensing unit function [hours/day]: Product use pattern [hours/year]: 4,380 4,380 Functional unit: 1 kw cooling capacity to reach -10 C at 30 C ambient temperature 1 kw cooling capacity to reach -25 C at 30 C ambient temperature Included Included Power input [kw]: Cooling capacity [kw]: Performance [COP]*: AEC [kwh/year]: 346, ,068 Price (ex VAT) [ ]: 55,000 70,000 Lifetime [years]: Refrigerant: R134a R404A Refrigerant charge [g]: Refrigerant leakage [% per annum]: 1 1 Weight of product [kg]: 2,757 3,171 External height [cm] : External width [cm] : External depth [cm] : Gross total (shipping) volume [m3] : Number of compressors: 2 2 Type of compressor: Semi-hermetic screw Semi-hermetic screw Power of compressor [W]: N.A. N.A. Capacity of compressor [W]: N.A. N.A. Weight of compressor [kg]: N.A. N.A. Compressor motor control [none/twospeed/vsd]: VSD compressor motor control (if applicable): Not included Not included Evaporator heat exchanger type and material: Stainless steel Stainless steel Evaporator face area [cm²]: N.A. N.A. Evaporator fan motor type: N.A. N.A. Evaporator fan motor power [W]: N.A. N.A. Evaporator fan motor control [none/twospeed/vsd]: Weight of evaporator module [kg]: N.A. N.A. Condenser cooling: Water-cooled Water-cooled Condenser heat exchanger type and material: Shell-tube / stainless Shell-tube / stainless N.A. N.A. 110 eto.carrier.com/litterature/prod_cat/en_30xa.pdf Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 147

442 Product characteristics Sub Base Case MT Sub Base Case LT steel steel Condenser face area [cm²]: N.A. N.A. Condenser fan motor type: N.A. N.A. Condenser fan motor power [W]: N.A. N.A. Condenser fan motor control [none/twospeed/vsd]: N.A. N.A. Weight of condenser module [kg]: N.A. N.A. Expansion valve type: Not included Not included 148 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

443 4.18. REMOTE CONDENSING UNITS Table 4-73: Characteristics of the remote condensing unit Sub Base Cases Product characteristics Sub Base Case MT Sub Base Case LT Product type/model/design: Packaged Packaged Test standard EN 13215:2000 EN 13215:2000 Internal cold storage temperature [ C]: Internal cold storage temperature range(s) ( C): 0-25 Air-on temperature (ambient temperature) [ C]: Product use pattern [hours/year]: 5,840 5,840 Functional unit: 1 kw of cooling capacity at evaporation temperature -10 C and ambient temperature +32 C 1 kw of cooling capacity at evaporation temperature - 35 C and ambient temperature +32 C Power input [kw]: Cooling capacity [kw]: Performance [COP]*: AEC [kwh/year]: 19,068 30,418 Price [ ]: 3,095 6,104 Product lifetime [years] 8 8 Refrigerant: R404A R404A Refrigerant charge [kg]: 7 6 Refrigerant leakage [% per annum]: Other features not covered above: - - Weight of product [kg]: External height [cm]: External width [cm]: External depth [cm]: Gross total (shipping) volume [m 3 ]: Number of compressors: 1 1 Type of compressor: Reciprocating hermetic Reciprocating hermetic Compressor motor control [none/twospeed/vsd]: None None Condenser cooling: Air-cooled Air-cooled Condenser heat exchanger type and material: steel steel Condenser face area [cm²]: N.A. N.A. Condenser fan motor type: On/Off On/Off VSD condenser fan motor control (if applicable): no No Condenser fan motor power [W]: * COP: Coefficient of Performance defined as the cooling capacity (kw) divided by the energy power input (kw) to the compressor Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 149

444 20-50 kw average: 20 kw Packaged condensing unit with single compressor Low temperature -35 C) kw average: 5-7 kw Table 4-74: Weighting factors for annual energy consumption of remote condensing units Configuration Evaporating temp. ( C) Cooling capacity (kw) Compress or type Hermetic reciproca ting Scroll Screw Rotary vane Hermetic reciproca ting Scroll Screw Compress or motor drive On/off 2 speeds VSD On/off 2 speeds VSD On/off 2 speeds VSD On/off 2 speeds VSD On/off 2 speeds VSD On/off 2 speeds VSD On/off 2 speeds Conde nser cooling Total market % AEC and power input conversion factors Average energy consumption per year (kwh) Average COP Air 15.9% Base Case LT 30, Water 0.0% 5% energy savings over Base Case LT 30, Air 0.9% 10% Energy savings over Base Case LT 27, Water 0.0% 5% energy savings over aircooled 27, Air 0.3% 10% energy savings over Base Case LT 27, Water 0.0% 5% energy savings over aircooled 27, Air 0.9% 10% energy savings over Base Case LT 27, Water 0.0% 5% energy savings over aircooled 27, Air 0.0% 10% Energy savings over on/off 26, Water 0.0% 5% energy savings over aircooled 26, Air 0.0% 10% Energy savings over on/off 23, Water 0.0% 5% energy savings over aircooled 23, Air 0.0% 10% savings over Base Case LT 27, Water 0.0% 5% energy savings over aircooled 27, Air 0.0% 10% Energy savings over on/off 26, Water 0.0% 5% energy savings over aircooled 26, Air 0.0% 10% Energy savings over on/off 24, Water 0.0% 5% energy savings over aircooled 24, Air 0.0% 10% energy savings over Base Case LT 27, Water 0.0% 5% energy savings over aircooled 27, Air 0.0% 10% Energy savings over on/off 26, Water 0.0% 5% energy savings over aircooled 26, Air 0.0% 10% Energy savings over on/off 24, Water 0.0% 5% energy savings over aircooled 24, Average power input given by Air 0.7% stakeholders AEC calculated using same ratio 91, AEC/PI as per Base Case LT Water 0.0% 5% energy savings over aircooled 91, Air 0.0% 10% Energy savings over on/off 87, Water 0.0% 5% energy savings over aircooled 87, Air 0.0% 10% Energy savings over on/off 82, Water 0.0% 5% energy savings over aircooled 82, Air 0.0% 10% savings over Hermetic reciprocating 82, Water 0.0% 5% energy savings over aircooled 82, Air 0.0% 10% Energy savings over on/off 78, Water 0.0% 5% energy savings over aircooled 78, Air 0.0% 10% Energy savings over on/off 74, Water 0.0% 5% energy savings over aircooled 74, Air 0.0% 10% savings over Hermetic reciprocating 82, Water 0.0% 5% energy savings over aircooled 82, Air 0.0% 10% Energy savings over on/off 78, Water 0.0% 5% energy savings over aircooled 78, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

445 Medium temperature (-10 C) kw average: 5-7 kw >50 kw average: 50kW Configuration Evaporating temp. ( C) Cooling capacity (kw) Compress or type Rotary vane Hermetic reciproca ting Scroll Screw Rotary vane Hermetic reciproca ting Scroll Compress or motor drive VSD On/off 2 speeds VSD On/off 2 speeds VSD On/off 2 speeds VSD On/off 2 speeds VSD On/off 2 speeds VSD On/off 2 speeds VSD On/off 2 speeds VSD Conde nser cooling Total market % AEC and power input conversion factors Average energy consumption per year (kwh) Average COP Air 0.0% 10% Energy savings over on/off 74, Water 0.0% 5% energy savings over aircooled 74, Air 0.0% 10% savings over Hermetic reciprocating 82, Water 0.0% 5% energy savings over aircooled 82, Air 0.0% 10% Energy savings over on/off 78, Water 0.0% 5% energy savings over aircooled 78, Air 0.0% 10% Energy savings over on/off 74, Water 0.0% 5% energy savings over aircooled 74, Average power input given by Air 0.2% stakeholders. AEC calculated using same ratio 241, AEC/PI as per Base Case LT Water 0.0% 5% energy savings over aircooled 229, Air 0.0% 10% Energy savings over on/off 229, Water 0.0% 5% energy savings over aircooled 217, Air 0.0% 10% Energy savings over on/off 217, Water 0.0% 5% energy savings over aircooled 206, Air 0.0% 10% savings over Hermetic reciprocating 217, Water 0.0% 5% energy savings over aircooled 206, Air 0.0% 10% Energy savings over on/off 206, Water 0.0% 5% energy savings over aircooled 195, Air 0.0% 10% Energy savings over on/off 195, Water 0.0% 5% energy savings over aircooled 185, Air 0.0% 10% savings over Hermetic reciprocating 217, Water 0.0% 5% energy savings over aircooled 206, Air 0.0% 10% Energy savings over on/off 206, Water 0.0% 5% energy savings over aircooled 195, Air 0.0% 10% Energy savings over on/off 195, Water 0.0% 5% energy savings over aircooled 185, Air 0.0% 10% savings over Hermetic reciprocating 217, Water 0.0% 5% energy savings over aircooled 206, Air 0.0% 10% Energy savings over on/off 206, Water 0.0% 5% energy savings over aircooled 195, Air 0.0% 10% Energy savings over on/off 195, Water 0.0% 5% energy savings over aircooled 185, Air 50.9% Base Case MT 19, Water 0.0% 5% energy savings over aircooled 18, Air 2.7% 10% Energy savings over on/off 18, Water 0.0% 5% energy savings over aircooled 17, Air 1.1% 10% Energy savings over on/off 17, Water 0.0% 5% energy savings over aircooled 16, Air 6.0% 10% savings over Hermetic reciprocating 17, Water 0.0% 5% energy savings over aircooled 16, Air 0.0% 10% Energy savings over on/off 16, Water 0.0% 5% energy savings over aircooled 15, Air 0.1% 10% Energy savings over on/off 14, Water 0.0% 5% energy savings over air- 13, Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 151

446 >50 kw average: 50kW kw average: 20 kw Configuration Evaporating temp. ( C) Cooling capacity (kw) Compress or type Screw Rotary vane Hermetic reciproca ting Scroll Screw Rotary vane Hermetic reciproca ting Compress or motor drive Conde nser cooling Total market % AEC and power input conversion factors Average energy consumption per year (kwh) Average COP cooled On/off Air 0.0% 10% savings over Hermetic reciprocating 17, Water 0.0% 5% energy savings over aircooled 16, Air 0.0% 10% Energy savings over on/off 16, speeds 5% energy savings over aircooled Water 0.0% 15, Air 0.0% 10% Energy savings over on/off 15, VSD 5% energy savings over aircooled Water 0.0% 14, On/off Air 0.0% 10% savings over Hermetic reciprocating 17, Water 0.0% 5% energy savings over aircooled 16, Air 0.0% 10% Energy savings over on/off 16, speeds 5% energy savings over aircooled Water 0.0% 15, Air 0.0% 10% Energy savings over on/off 15, VSD 5% energy savings over aircooled Water 0.0% 14, Average power input given by stakeholders Air 9.5% 60, AEC calculated using same ratio On/off AEC/PI as per Base Case MT Water 0.0% 5% energy savings over aircooled 57, Air 0.5% 10% Energy savings over on/off 57, speeds 5% energy savings over aircooled Water 0.0% 54, Air 0.2% 10% Energy savings over on/off 54, VSD 5% energy savings over aircooled Water 0.0% 51, On/off Air 1.1% 10% savings over Hermetic reciprocating 54, Water 0.0% 5% energy savings over aircooled 51, Air 0.0% 10% Energy savings over on/off 51, speeds 5% energy savings over aircooled Water 0.0% 48, Air 0.0% 10% Energy savings over on/off 48, VSD 5% energy savings over aircooled Water 0.0% 46, On/off Air 0.0% 10% savings over Hermetic reciprocating 54, Water 0.0% 5% energy savings over aircooled 51, Air 0.0% 10% Energy savings over on/off 51, speeds 5% energy savings over aircooled Water 0.0% 48, Air 0.0% 10% Energy savings over on/off 48, VSD 5% energy savings over aircooled Water 0.0% 46, On/off Air 0.0% 10% savings over Hermetic reciprocating 54, Water 0.0% 5% energy savings over aircooled 51, Air 0.0% 10% Energy savings over on/off 51, speeds 5% energy savings over aircooled Water 0.0% 48, Air 0.0% 10% Energy savings over on/off 48, VSD 5% energy savings over aircooled Water 0.0% 46, Average power input given by stakeholders Air 3.0% 136, AEC calculated using same ratio On/off AEC/PI as per Base Case MT Water 0.2% 5% energy savings over aircooled 129, Air 0.2% 10% Energy savings over on/off 129, speeds 5% energy savings over aircooled Water 0.0% 123, VSD Air 0.1% 10% Energy savings over on/off 122, Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

447 >50 kw average: 50kW Packaged condensing unit with twin compressors or more Medium temperature (-10 C) kw average: 20 kw >50 kw average: 50kW Low temperature (-35 C) kw average: 20 kw Configuration Evaporating temp. ( C) Cooling capacity (kw) kw kw Compress or type Scroll Screw Rotary vane Compress or motor drive On/off 2 speeds VSD On/off 2 speeds VSD On/off 2 speeds VSD scroll - screw - scroll - screw - scroll - screw - scroll - screw - Conde nser cooling Total market % AEC and power input conversion factors Average energy consumption per year (kwh) Average COP Water 0.0% 5% energy savings over aircooled 116, Air 0.3% 10% savings over Hermetic reciprocating 122, Water 0.0% 5% energy savings over aircooled 116, Air 0.0% 10% Energy savings over on/off 116, Water 0.0% 5% energy savings over aircooled 110, Air 0.0% 10% Energy savings over on/off 110, Water 0.0% 5% energy savings over aircooled 105, Air 0.0% 10% savings over Hermetic reciprocating 122, Water 0.0% 5% energy savings over aircooled 116, Air 0.0% 10% Energy savings over on/off 116, Water 0.0% 5% energy savings over aircooled 110, Air 0.0% 10% Energy savings over on/off 110, Water 0.0% 5% energy savings over aircooled 105, Air 0.0% 10% savings over Hermetic reciprocating 122, Water 0.0% 5% energy savings over aircooled 116, Air 0.0% 10% Energy savings over on/off 116, Water 0.0% 5% energy savings over aircooled 110, Air 0.0% 10% Energy savings over on/off 110, Water 0.0% 5% energy savings over aircooled 105, % - Air 0.8% Water 0.0% Air 0.0% Water 0.0% Air 0.2% Water 0.0% Air 0.0% Water 0.0% 10% savings over single compressor 5% energy savings over aircooled 10% savings over Hermetic reciprocating 5% energy savings over aircooled 10% savings over single compressor 5% energy savings over aircooled 10% savings over Hermetic reciprocating 5% energy savings over aircooled % - Air 3.0% Water 0.0% Air 0.0% Water 0.0% Air 0.9% Water 0.0% Air 0.1% Water 0.0% 10% savings over single compressor 5% energy savings over aircooled 10% savings over Hermetic reciprocating 5% energy savings over aircooled 10% savings over single compressor 5% energy savings over aircooled 10% savings over Hermetic reciprocating 5% energy savings over aircooled 74, , , , , , , , , , , , , , , , Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 153

448 This page is left intentionally blank 154 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

449 ANNEX 4-2: Component material proportions Compressor Typical compressors used in the majority of refrigeration and freezing equipment are reciprocating hermetic compressors and present the following characteristics: a kw cooling capacity (at an evaporating temperature of -10 C, measured with EN 12900, condensing temperature of +55 C) and a weight between kg. The approximated material composition of this type of compressors was estimated together with compressor manufacturers during the Lot 12 study. The data collected was then averaged and showed the following distribution of materials for a 10 kg compressor (Table 4-75). Table 4-75: Material composition of a typical hermetic piston compressor Materials Weight in g Category Material Compression Module cast iron of the compressor casing Ferro 23-Cast iron steel of the compressor Ferro 21-St sheet galv. steel for motor lamination Ferro 24-Ferrite aluminium Non-ferro 26-Al sheet/extrusion rubber 10 1-BlkPlastics 4-PP epoxy 10 2-TecPlastics 14-Epoxy ester oil Misc. polypropylene 10 1-BlkPlastics 4-PP copper Non-ferro 28-Cu winding wire PET 30 1-BlkPlastics 2-HDPE TOTAL Heat exchangers The following material composition for evaporator and the condenser was identified during the Lot 12 study. The same assumptions were used here if data was not given by the manufacturer. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 155

450 Table 4-76: Material composition of the heat exchangers Materials Weight in % Category Material Evaporator Aluminium fins 2/3 mass 4-Non-ferro 26-Al sheet/extrusion Suction line 1/3 mass 4-Non-ferro 30-Cu tube/sheet Condenser Suction line 1/2 mass 4-Non-ferro 30-Cu tube/sheet Aluminium fins 1/4 mass 4-Non-ferro 26-Al sheet/extrusion Steel 1/4 mass 3-Ferro 22-St tube/profile Fans and fan motors For the evaporator and condenser fans motors, the identified components show the following characteristics: the overall weight of the fan module is g (around 500 g for the motor with power input of 18 W). The fan is made with an aluminium blade and is connected to a shaded pole motor. The material composition is presented in Table It mostly comprises steel, plastics and copper. In some cabinets, the blade of the evaporator fans can also be made of plastic. However the typical fan was identified as fitted with aluminium blades. Table 4-77: Material composition of a typical fan and fan motor Materials Weight in g Category Material Fan blade Aluminium Non-ferro 26-Al sheet/extrusion Fan motor Steel Ferro 21-St sheet galv. Iron Ferro 24-Ferrite Copper Non-ferro 28-Cu winding wire PA TecPlastics 11-PA 6 Electronics Electronics 98-controller board TOTAL Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

451 ANNEX 4-3: Service cabinets EcoReport results and detailed BOM HT LT Material production Manufacture Distribution Use EOL Figure 4-56: Waste (non-hazardous) related to each phase of the life cycle of service cabinet (g) HT LT Material production Manufacture Distribution Use EOL Figure 4-57: Waste (hazardous) related to each phase of the life cycle of service cabinet (g) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 157

452 HT LT Material production Manufacture Distribution Use EOL Figure 4-58: Acidification related to each phase of the life cycle of service cabinet (gso2 eq.) HT LT Material production Manufacture Distribution Use EOL Figure 4-59: POPs related to each phase of the life cycle of service cabinet (ng i-teq) 158 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

453 HT LT 0 Material production Manufacture Distribution Use EOL Figure 4-60: VOCs related to each phase of the life cycle of service cabinet (g) HT LT Material production Manufacture Distribution Use EOL Figure 4-61: Heavy metals related to each phase of the life cycle of service cabinet (mgni eq.) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 159

454 HT LT Material production Manufacture Distribution Use EOL Figure 4-62: PAHs related to each phase of the life cycle of service cabinet (mgni eq.) HT LT Material production Manufacture Distribution Use EOL Figure 4-63: PMs related to each phase of the life cycle of service cabinet (g) 160 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

455 HT LT Material production Manufacture Distribution Use EOL Figure 4-64: Heavy metals (water) related to each phase of the life cycle of service cabinet (mg Hg/20) HT LT Material productionmanufacture Distribution Use EOL Figure 4-65: Eutrophication related to each phase of the life cycle of service cabinet (g PO 4 ) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 161

456 Table 4-78: Materials inputs in the EcoReport tool for service cabinets Pos MATERIALS Extraction & Production Weight Category Material or Process nr Description of component in g Click &select select Category first! 1 Housing 2 Insulated casing 3 External housing 4 panels pre coating (external panels) Coating 38-pre-coating coil 5 chassis (cabinet structure) Ferro 21-St sheet galv. 6 mounting internal components Ferro 21-St sheet galv. 7 inner cabinet lining BlkPlastics 7-HI-PS 8 lateral motor space BlkPlastics 4-PP 9 adhesive expanded TecPlastics 16-Flex PUR 10 EPS parts BlkPlastics 6-EPS 11 PVC parts BlkPlastics 8-PVC 12 fan housing BlkPlastics 7-HI-PS 13 back grid (condenser) Ferro 22-St tube/profile 14 front grid BlkPlastics 7-HI-PS 15 top panel cover BlkPlastics 10-ABS 16 PC parts (insert) 48 2-TecPlastics 12-PC 17 plastic ring 2 1-BlkPlastics 1-LDPE 18 nylon parts 22 2-TecPlastics 11-PA 6 19 Foam insulation 20 polyurethane TecPlastics 15-Rigid PUR 21 Shelves & Grids 22 shelves Ferro 22-St tube/profile 23 Door 24 steel sheet Coating 38-pre-coating coil 25 support frame Ferro 22-St tube/profile 26 handle and plastic cover BlkPlastics 10-ABS 27 plastics (frame) BlkPlastics 8-PVC 28 polyurethane TecPlastics 15-Rigid PUR 29 gasket BlkPlastics 8-PVC 30 spring Non-ferro 32-ZnAl4 cast 31 plastic sheet Misc. 32 plastics parts 12 2-TecPlastics 11-PA 6 33 Components for assembling 34 screws, etc Ferro 23-Cast iron 35 sealing mastic Misc. Pos MATERIALS Extraction & Production Weight Category Material or Process nr Description of component in g Click &select select Category first! 42 Evaporation module 43 Evaporator 44 roll bond Non-ferro 26-Al sheet/extrusion 162 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

457 Pos MATERIALS Extraction & Production Weight Category Material or Process nr Description of component in g Click &select select Category first! 45 brackets 25 1-BlkPlastics 10-ABS 46 copper high pressure line 80 4-Non-ferro 30-Cu tube/sheet 47 Evaporator fans 48 Frame 49 iron Ferro 25-Stainless 18/8 coil 50 Blades 51 fan blades 80 4-Non-ferro 26-Al sheet/extrusion 52 Evaporator fans motors 53 aluminium 75 4-Non-ferro 27-Al diecast 54 iron Ferro 24-Ferrite 55 copper Non-ferro 28-Cu winding wire 56 PVC parts 38 1-BlkPlastics 8-PVC 57 Evaporation tray 58 drip tray BlkPlastics 4-PP 59 PVC pipe 20 1-BlkPlastics 8-PVC 60 Compression module 61 Compressor 62 cast iron of the compressor casing Ferro 23-Cast iron 63 steel Ferro 24-Ferrite 64 aluminium Non-ferro 27-Al diecast 65 rubber 15 1-BlkPlastics 4-PP 66 ester oil Misc. 67 copper Non-ferro 28-Cu winding wire 68 polyptropylen 15 1-BlkPlastics 4-PP 69 PET 40 1-BlkPlastics 2-HDPE 70 Condensation module 71 Condenser 72 steel Ferro 22-St tube/profile 73 brackets 18 2-TecPlastics 11-PA 6 74 Condenser fans 75 Frame 76 iron Ferro 24-Ferrite 77 Blades 78 fan blades 80 4-Non-ferro 26-Al sheet/extrusion 79 Condenser fans motors 80 aluminium 75 4-Non-ferro 27-Al diecast 81 iron Ferro 24-Ferrite 82 copper Non-ferro 28-Cu winding wire 83 PVC parts 38 1-BlkPlastics 8-PVC 84 Expansion valve module 85 capillary tube 22 4-Non-ferro 30-Cu tube/sheet Pos MATERIALS Extraction & Production Weight Category Material or Process Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 163

458 Pos MATERIALS Extraction & Production Weight Category Material or Process nr Description of component in g Click &select select Category first! nr Description of component in g Click &select select Category first! 89 Electric assembly (not included in other modules) 90 Electric panel 91 electrical box 40 1-BlkPlastics 10-ABS 92 Cables 93 cables plastic parts BlkPlastics 8-PVC 94 cables metal parts Non-ferro 29-Cu wire 95 terminal (plug) 30 6-Electronics 45-slots / ext. ports 96 Packaging 97 Manuals 98 general instructions 67 7-Misc. 57-Office paper 99 plastics (LDPE) 7 1-BlkPlastics 1-LDPE 100 Protection 101 pallet (wood) Misc. 102 plastics (film) BlkPlastics 1-LDPE 103 EPS parts BlkPlastics 6-EPS 104 PVC parts 25 1-BlkPlastics 8-PVC 105 Miscellaneous 106 Temperature control and display system 107 set thermostat 55 3-Ferro 24-Ferrite 108 set thermostat 15 2-TecPlastics 12-PC 109 LCD screen 30 6-Electronics 42-LCD per m2 scrn 110 Pipes in the refrigeration system 111 copper tubes 57 4-Non-ferro 30-Cu tube/sheet 112 Others 113 drain pipes 6 1-BlkPlastics 7-HI-PS 114 knitting alloy 9 4-Non-ferro 29-Cu wire 115 lock 65 3-Ferro 24-Ferrite 164 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

459 ANNEX 4-4: Blast cabinets EcoReport results Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-66: GER related to each phase of the life cycle of blast cabinet (MJ) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 165

460 Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-67: Process water related to each phase of the life cycle of blast cabinet (ltr) Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-68: Waste (non-hazardous) related to each phase of the life cycle of blast cabinet (g) 166 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

461 Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-69: Waste (hazardous) related to each phase of the life cycle of blast cabinet (g) Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-70: GWP related to each phase of the life cycle of blast cabinet (kg CO2 eq.) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 167

462 Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-71: Acidification related to each phase of the life cycle of blast cabinet (gso2 eq.) Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-72: POPs related to each phase of the life cycle of blast cabinet (ng i-teq) 168 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

463 Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-73: VOCs related to each phase of the life cycle of blast cabinet (g) Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-74: Heavy metals to air related to each phase of the life cycle of blast cabinet (mgni eq.) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 169

464 Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-75: PAHs related to each phase of the life cycle of blast cabinet (mgni eq.) Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-76: PMs related to each phase of the life cycle of blast cabinet (g) 170 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

465 Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-77: Heavy metals (water) related to each phase of the life cycle of blast cabinet (mg Hg/20) Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-78: Eutrophication related to each phase of the life cycle of blast cabinet (g PO4) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 171

466 This page is left intentionally blank 172 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

467 ANNEX 4-5: Walk-in cold rooms EcoReport results Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-79: Waste (non-hazardous) related to each phase of the life cycle of walk-in cold room (g) Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-80: Waste (hazardous) related to each phase of the life cycle of walk-in cold room (g) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 173

468 Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-81: Acidification related to each phase of the life cycle of walk-in cold room (gso2 eq.) Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-82: POPs related to each phase of the life cycle of walk-in cold room (ng i-teq) 174 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

469 Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-83: VOCs related to each phase of the life cycle of walk-in cold room (g) Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-84: Heavy metals related to each phase of the life cycle of walk-in cold room (mgni eq.) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 175

470 Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-85: PAHs related to each phase of the life cycle of walk-in cold room (mgni eq.) Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-86: PMs related to each phase of the life cycle of walk-in cold room (g) 176 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

471 Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-87: Heavy metals (water) related to each phase of the life cycle of walk-in cold room (mg Hg/20) Prod. Material Prod. Manuf. Distribution Use EOL Figure 4-88: Eutrophication related to each phase of the life cycle of walk-in cold room (g PO 4 ) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 177

472 This page is left intentionally blank 178 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

473 ANNEX 4-6: Process chillers EcoReport results Material production Manufacture Distribution Use EOL MT LT Figure 4-89: GER related to each phase of the life cycle of process chiller (MJ) MT LT Material production Manufacture Distribution Use EOL Figure 4-90: Process water related to each phase of the life cycle of process chiller (ltr) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 179

474 Material production Manufacture Distribution Use EOL MT LT Figure 4-91: Waste (non-hazardous) related to each phase of the life cycle of process chiller (g) Material production Manufacture Distribution Use EOL MT LT Figure 4-92: Waste (hazardous) related to each phase of the life cycle of process chiller (g) 180 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

475 MT LT Material production Distribution EOL Figure 4-93: GWP related to each phase of the life cycle of process chiller (kg CO2 eq.) Material production Manufacture Distribution Use EOL MT LT Figure 4-94: Acidification related to each phase of the life cycle of process chiller (gso2 eq.) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 181

476 Material production Manufacture Distribution Use EOL MT LT Figure 4-95: POPs related to each phase of the life cycle of process chiller (ng i- Teq) MT LT Material production Manufacture Distribution Use EOL Figure 4-96: VOCs related to each phase of the life cycle of process chiller (g) 182 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

477 MT LT 0 Material production Manufacture Distribution Use EOL Figure 4-97: Heavy metals related to each phase of the life cycle of process chiller (mgni eq.) MT LT Material production Manufacture Distribution Use EOL Figure 4-98: PAHs related to each phase of the life cycle of process chiller (mgni eq.) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 183

478 MT LT 0 Material production Manufacture Distribution Use EOL Figure 4-99: PMs related to each phase of the life cycle of process chiller (g) Material production Manufacture Distribution Use EOL MT LT Figure 4-100: Heavy metals (water) related to each phase of the life cycle of process chiller (mg Hg/20) 184 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

479 Material production Manufacture Distribution Use EOL Figure 4-101: Eutrophication related to each phase of the life cycle of process chiller (g PO 4 ) MT LT Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 185

480 This page is left intentionally blank 186 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

481 ANNEX 4-7: Remote condensing units EcoReport results MT LT 0 Material production Manufacture Distribution Use EOL Figure 4-102: Waste (non-hazardous) related to each phase of the life cycle of condensing unit (g) MT LT Material production Manufacture Distribution Use EOL Figure 4-103: Waste (hazardous) related to each phase of the life cycle of condensing unit (g) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 187

482 MT LT 0 Material production Manufacture Distribution Use EOL Figure 4-104: Acidification related to each phase of the life cycle of condensing unit (gso2 eq.) MT LT Material production Manufacture Distribution Use EOL Figure 4-105: POPs related to each phase of the life cycle of condensing unit (ng i-teq) 188 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

483 MT LT Material production Manufacture Distribution Use EOL Figure 4-106: VOCs related to each phase of the life cycle of condensing unit (g) MT LT Material production Manufacture Distribution Use EOL Figure 4-107: Heavy metals related to each phase of the life cycle of condensing unit (mgni eq.) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 189

484 MT LT Material production Manufacture Distribution Use EOL Figure 4-108: PAHs related to each phase of the life cycle of condensing unit (mgni eq.) MT LT 0 Material production Manufacture Distribution Use EOL Figure 4-109: PMs related to each phase of the life cycle of condensing unit (g) 190 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

485 MT LT Material production Manufacture Distribution Use EOL Figure 4-110: Heavy metals (water) related to each phase of the life cycle of condensing unit (mg Hg/20) MT LT Material production Manufacture Distribution Use EOL Figure 4-111: Eutrophication related to each phase of the life cycle of condensing unit (g PO 4 ) Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 191

486 Annex 4-8: Dessert and beverage machines, water dispensers and ice-makers DESSERT AND BEVERAGE MACHINES Product description at component level Concerning energy consumption of individual components, not much data is available. Technical drawings (Figure 4-112) are provided only for plug-in slush machines and ice-cream machines as the principle of the general design is similar for all beverage and dessert machines. In case of remote dessert and beverage machines, the equipment does not comprise the compressor and the condenser. evaporator: it is in direct contact with the product to cool. In typical ice cream machines, the evaporator is mounted right behind the dispensing head (Figure 4-112, 4). Here there are no uses of fan motors at the evaporator. However, motors are used for the stirrer. Stirrer: it is driven typically by electric motors, therefore, this component has a direct impact in the overall electricity consumption of dessert and beverage machines. Nevertheless, the most important role of the stirrer is to give the final product the desired texture. Stirrers are designed to break up crystals in the freezing mixture while allowing a good freezing process of the final product (i.e. ice cream, slush). compressor: The function of compressor(figure 4-112, 1)in dessert and beverage machines is already described in expansion device (Figure 4-112, 3): both thermostatic valves and capillary tubes are used in dessert and beverage machines. condenser and condenser fan (Figure 4-112, 2). The function of condenser in dessert and beverage machines is already described in tank: the tank (Figure 4-112, 5) is where the beverage or dessert is stored. In some cases, the tank can be transparent Some equipment is available that includes a heat treatment option for sterilising dairy products. This is a relatively new advancement where the machine provides a daily heating and cooling cycle to safely maintain dairy products for longer, before a complete disassembly and cleaning is required. Moreover, some beverage machines also include an ice making function. 192 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4

487 Figure Typical plug-in slush machine 111 (left) and ice cream machine (right) 112 Dessert and beverage machines features affecting energy consumption levels Based on the description of the components of dessert and beverage machines, this section introduces product features that can affect the overall energy consumption of this kind of products. Location of the condensing unit: remote vs. plug-in Based on the findings of the preparatory study to TREN Lot 12 on commercial refrigeration, and on qualitative analysis, it is assumed that plug-in beverage and dessert machines usually present higher energy consumption than remote ones. Type of beverage or dessert produced The type of dessert or beverage produced will determine the operating temperature of the machine and might imply the use of a stirring device driven by a motor. 111 Source: Source: COLDELITE; UC711 G/P; Soft Serve Freezer Spare Parts Manual; COLDELITE CORPORATION OF AMERICA. Proposal for Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4 193

488 4.20. WATER DISPENSERS Product description at component level Figure (a) Typical water cooler, (b) Typical Water fountain bottle support (only for water coolers): Item 1 in Figure 4-113(a) water reservoir: Item 4 in Figure 4-113(a). The function of this water reservoir is to store chilled water so that the user does not have to wait until water gets the desired low temperature. water reservoir insulation jacket (only for water coolers): item 2 in Figure 4-113(a). The main function of this insulation jacket is to avoid heat transfer from the surroundings towards the water reservoir. Without this component the cooling load demand in the compressor would be higher. condenser: Item 5 in Figure 4-113(a) and Item 24 in Figure 4-113(b). The function of condenser in water dispensers as well as its role in energy consumption is already described in Due to space restrictions, water dispensers generally use water-cooled condenser. evaporator: Item 3 in Figure 4-113(a) and Item 16 in Figure 4-113(b). The function of the evaporator in water dispensers as well as its role in energy consumption is already described in compressor: Item 7 in Figure 4-113(a) and Item 22 in Figure 4-113(b). The function of the compressor in water dispensers as well as its role in energy consumption is already described in dispenser valves: Item 10 in Figure 4-113(a) and Item 2 in Figure 4-113(b). pre-cooler: (water fountains only) Item 17 in Figure 4-113(b). As unused water has low temperature, a heat exchanger might be connected to the drain pipe in order to transfer heat before it is wasted. This component reduces the cooling load demand in the compressor. 194 Preparatory Study for Eco-design Requirements of EuPs ENTR Lot 1: Refrigerating and freezing equipment Task 4