Refrigeration Magazine February 2016

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February 2016 issue of Refrigeration Magazine features ways to save on energy costs and the Spring Ice Convention season.


  • FEBRUARY 2016

    R438A, Ozone, Compressors, Energy Costs AND SPRING CONVENTION SEASON

    Plus much more, inside this issue!

  • 2 REFRIGERATION Magazine February 2016

  • February 2016 REFRIGERATION Magazine 3

    6 TIPS FOR CONTROLLING ENERGY COSTS ON INDUSTRIAL REFRIGERATION SYSTEMSCompressors and condensers account for most energy usage







    REMEMBER THE OZONE HOLE? IT'S BACKWell, it actually never really left



    9 Schedule

    10 Looking Back at the SIE A decade ago

    INDUSTRY NEWSDon Carpenter and AIS honored; Robert Salter of Prestige Ice dies In crash

    RETROFITTING R-438A: EASIER THAN IT SOUNDSSimplified tips and facts

    CALENDARUpcoming industry events

    LOOKING BACK THROUGH THE PAGES OF REFRIGERATIONA 1958 Letter To The Ice Industry, by my father, John Yopp. (There is a timely and interestingly familiar air to his letter.)


    Table ofCONTENTS

    DEPARTMENTSspICE Digging out in time to dig back in 4AD INDEX A list of our advertisers 26CLASSIFIED ADS Classified advertisements by region 26



    Mary Y. CronleyEditor/ 819-5446

    Joe CronleySenior Staff 295-5712

    Markurious Marketing Group, LLCArt 439-6534


    Mary Y. CronleyEditor/ 819-5446

    Established as ICE in 1906, Refrigeration Magazine is published thirteen times a year, including the Annual Buyer's Guide.

    Postmaster: Send notice by form 3579 to:Refrigeration Magazine260 Lakeview Ridge EastRoswell, GA 30076

    Annual Subscriptions: US: $49/year or $79/two yearsInternational: $79/year

    Single Copies: $6/copy

    Copyright 2015 by REFRIGERATION Magazine. All rights reserved.

    February 2016Vol. 199 No. 2ISSN #0034-3137




  • 4 REFRIGERATION Magazine February 2016

    Digging Out In Time To Dig Back InHow ironic it is that a packaged ice plants major off season projects might be delayed by ice. Well, primarily snow, but along with it a lot of ice. The storm that shut down much of the east coast for days in January has slowed down trucks, airlines, personnel, and may put many plans days or weeks behind.

    In California, the only ingredient in packaged ice is at a premium. Theres no word of any consumption restrictions, and its even possible that drought conditions have increased demand for our product. Even when rains return to expected pre-El Nino levels, it will be years before reservoirs, water tables and agriculture return to normal. Long run, the decline in economic activity from the drought may hurt packaged ice more than the weather helps it.

    Come May or June, whenever your high season kicks in, will any of this make a difference? No.

    Your customers will still demand ample supplies of high quality product this summer. Your season will still depend on vagaries of weather not the weather this winter, not the cumulative rainfall the weather on Memorial Day and Independence Day. It will still depend on turnout at your area art and music festivals, local traditions and observances, beaches, lakes and rivers. Sunshine is our best friend, and the more people can get out of the house, the better for packaged ice.

    So keep moving forward on that additional ice maker, that new rake bin, that remodeled packaging line. Dont cancel the new truck order. February is the cruelest month for anyone who isnt a winter sports enthusiast. Its dark, its cold, theres no more football and basketball has something like six more months to go. Even hockey goes on until after Memorial Day.

    One thing I love about every single day after December 21 is that the days get longer. I notice it already: in this latitude it gets dark about 5:30 in the dead of winter, but today as I pulled in it was still dusky at 6:20. It only changes about a minute a day (I looked it up) but it does change.

    The snow piles will melt in your city. Your construction project will get back on schedule. Your reservoirs will fill one day, the wells will pump clear again, your farmers will shake almond trees and pull lettuce, tomatoes and asparagus out of the ground. People will get on the subway, get in their cars, or just walk into their backyards and will once again enjoy sunshine and warmth.

    Theyll need lots of packaged ice to do it. Dont worry about the thousands or tens or hundreds of thousands of dollars youre investing in plant improvements. Year in, year out this industry earns them back. Just be ready for the first day it hits 70. If it hasnt happened before you read this, I promise you it will soon.

    Id also love a photo of your snowbound plants or trucks. Please email me any images to and I will make a section in an upcoming issue. Hopefully nobody will still be digging out when you read this, but Id like to hear your stories.

    Mary Yopp CronleyEditor, Refrigeration Magazine

    "I'd also love a photo of your snowbound plants or trucks. Please email me any images to and I will make a section in an upcoming issue. Hopefully nobody will still be digging out when you read this, but I'd like to hear your stories."


    Summer will be here before you know it. Check your

    stock shelves for inventory. If your Hamer bag closers need a rebuild, do it now.

    - Mike Landino, Polar Temp


  • Tips for controlling energy costs on industrial refrigeration systemsBy Luke Facemyer

    6 REFRIGERATION Magazine February 2016

    An integrated approach to optimizing the mechanical system along with an automation strategy is one of the most effective ways to reduce energy costs.

    Refrigeration systems account for the largest variable cost of a typical packaged ice plant. As energy costs continue to increase, engineers are looking for ways to manage these costs and operate these systems more efficiently.

    An integrated approach to optimizing the mechanical system, along with an automation strategy, is one of the most effective ways to reduce energy costs. Too often, engineers look to optimize each individual component of their system rather than looking at the system as a single, integrated unit. Every time a new piece of equipment is added to the system, if its not properly optimized within the scope of the entire system, youll end up with wasted energy and operational inefficiencies. Prior to adding new equipment, its important to obtain baseline data on the amount of energy a system consumes. Thats the only way to accurately measure the impact a new piece of equipment has on the overall system.

    The primary factors that influence the energy efficiency of a refrigeration system are the efficiency of the systems design and the refrigerant used, the condition of the equipment, the control strategy, and the load profile of the system (deviation of the operating cooling loads from the design cooling loads).

    Compressors and condensers are the two components that account for the greatest energy usage.

    Compressors Compressors account for the majority of the energy consumption in a refrigeration system and therefore should be carefully selected to ensure they match the load and can be staged and sequenced effectively. Screw compressors are most efficient operating at full load; at part-load conditions, they become increasingly less efficient. The addition of variable frequency drives (VFD) to a screw compressor will increase the part-load efficiency. A reciprocating compressor has much better part-load efficiency and may be a good choice for smaller loads.

    Condensers Condensers are typically the second highest energy usage component of a refrigeration system. Adding VFDs to condenser fans can have several advantages and will give better condensing pressure control, which can smooth system operation. Condensers need to be sized for peak loads, meaning for all loads except for a few peak conditions when they are oversized. Reducing the fan speed to match the capacity will produce considerable horsepower savings.

    Here are steps engineers can take to optimize a refrigeration system to achieve the greatest energy efficiency:

    Optimize set points, as condensing pressure should typically be run as low as possible. Suction pressure should be run as low as possible while still maintaining the desired room/product temperatures. Adjusting suction pressure up 1 degree could mean a 1.5 percent savings for those compressors.

    Compressors should be sized to match the loads as closely as possible. It is good practice to include different sized machines and sequence them properly to keep the machines as fully loaded as possible. For large systems, large compressors handle the majority of the load with a smaller compressor included as a trim compressor to handle the swings. This will keep the larger compressor fully loaded at all times. The trim compressor could have a VFD to further increase savings. Two equally sized compressors, each running at 50 percent capacity, can require 30 percent more HP than one compressor running at 100 percent, so proper selection upfront and good sequencing is important.

    Install VFDs on screw compressors to optimize mechanical efficiencies of the machines. The best approach is to set the slide valve position at 100 percent and vary the RPM of the motor according to the refrigeration needs of the machine, which allows it to run more efficiently.

    Plant Maintenance

  • February 2016 REFRIGERATION Magazine 7

    Refrigeration Magazine offers a once-a-year opportunity for suppliers to showcase their companies and the products or services they supply to the packaged ice industry in our 2016 Buyer's Guide. The Refrigeration Magazine Buyer's Guide is the most trusted and referenced product resource in our industry.

    General listings are FREE and include a company description, website, association memberships and contact information including mailing address, phone number, fax number and email address. Advertisers are differentiated with their logo included with their listing and an advertiser icon in the index.

    Equipment listings are due by Friday, February 19. Visit us online at to view your listing in our 2015 Buyer's Guide and email to let us know if you have changes to your listing. New listings can be submitted via the online form on our website.

    12 REFRIGERATION Magazine Buyer's Guide March 2015


    14650 28th Ave. NPlymouth, MN 55447Phone: 763-231-0100Toll-Free: 800-927-4674Fax: 763-231-0101Email: packaging@hamerinc.comWebsite:

    Automatic form/ ll/seal packaging systems, bag handle former, bag gusset former, automatic bag closers, heat sealers and balers. Factory training seminars, onsite training and service. Factory rebuilding of used equipment.



    225 Spartangreen Blvd.Duncan, SC 29334Phone: 864-486-4000Fax: 864-486-4412Email: sales@hayssensandiacre.comWebsite: www.hayssensandiacre.comContact: Margaret Valinskimargaret.valinski@hayssensandiacre.comDirect Phone: 864-486-4251

    HayssenSandiacre is a global manufacturer of exible packaging systems that ll and bag thousands of food products including IQF, liquids, powders, frozen food, cheese, coffee, produce, snacks, bakery and pet food; as well as a wide range of non-food products. HayssenSandiacres packaging systems are designed and manufactured to maximize the ef ciency and lifetime value of your packaging line.



    P.O. Box 497808 Bob Posey StreetHenderson, KY 42419Toll-Free: 800-633-3031Email: info@herculesvanbodies.comWebsite: www.herculesvanbodies.comContact: Chip Honse, Sales Manager

    Custom built Insulated Van Bodies from 8 ft. slip-in to 28 ft. body.



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    Pressure GaugesGlycerin Filled Stainless30/0/150 and 30/0/3002-1/2 Dial $36.00ea.

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    Sulfur Sticks

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    Litmus Paper $6.50 / book


    Cornell, Dunham Bush, Frick, F.E.S. GEA, Sabroe, Stal, Sullair, Viking, York are registered trademarks. Fuller is a registeredtrademark of FL Smidth Inc. Mycom is a registered trademark of Mayekawa; Vilter is a registered trademark of Emerson Climate.

    Ammonia Hoses

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    Replacement parts for use in your VilterWe stock an extensive line of replacement parts for

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    From a spring to a package Farleys can handle it

    Valves Parker, R/S, Danfoss, Phillips, Hansen, Shank, Sporlan, Wolf Linde

    Replacement Coalescing &Oil Filters available


    Sample Listing

    COMING IN MARCH! Install VFDs on condenser motors to stabilize head pressure and prevent the motors from heavy repeats and intense start/stop cycles. This will allow the fans to change speeds so they dont continually stop and start, which requires additional energy and results in mechanical wear. The biggest payback from a VFD will be on systems with variable loads (some systems run at 100 percent almost all the time, and in these cases, a VFD will actually be less efficient since the VFD has inherent losses).

    Use of floating head pressure to maintain the ideal temperature for compressor and condenser operations is important. Higher condensing temperatures require compressors to work harder while lower temperatures require less power. Find the optimal break-even point where the condensers and compressors are cumulatively using the lowest overall horsepower requirements.

    Lower temperature systems should thoroughly evaluate the efficiency of a two-stage or possibly a cascade system. Depending on the conditions, the savings over a single stage system can be considerable.

    A completely integrated automation system can run a machine room to ensure efficiency and automate temperature controls within zones. Automating defrost cycles to sequence at different times can result in significant energy savings. An automated system can make calculations and adjustments constantly, where a system operated manually requires constant operator attention, and is susceptible to human error and will react much slower.

    Remote monitoring can have a significant impact on the bottom line, reducing energy, maintenance and overall operating costs. If youve recently upgraded your refrigeration controls system or are in the process of upgrading, its important to ensure your new system offers remote access. This will allow for speedy diagnostics, offsite troubleshooting capabilities, and constant monitoring, all with a big picture view of the entire system and all...