The refrigeration industry is under increasing pressure to adopt environmentally friendly practices. A primary focus of recent legislation is the phase-out of synthetic refrigerants with high global warming potentials (GWPs) and ozone depletion effects. This shift is forcing companies to explore alternatives that align with both environmental goals and regulatory standards. Among these alternatives, CO₂ (carbon dioxide) systems appear as a highly viable option, offering efficiency, cost-effectiveness, and a significantly reduced environmental impact.
Why CO₂?
CO₂ systems present numerous advantages over synthetic refrigerants. With zero ozone depletion potential and a GWP of just 1, CO₂ has a minimal environmental footprint, making it an attractive choice for companies looking to future proof their operations. Beyond its eco-friendly profile, CO₂ is highly effective across various climates and scales, making it suitable for a wide range of applications in the industrial refrigeration sector.
Key considerations when switching to CO₂
However, adopting CO₂ as a refrigerant isn’t without its challenges. CO₂ is a high-pressure refrigerant, requiring specialized equipment capable of withstanding elevated pressures and temperatures. During standstill periods, ambient temperatures can push the CO₂ system to its critical temperature, leading to pressures that exceed standard levels. Companies switching to CO₂ need to ensure that their components, especially sensors, are built to handle these extreme conditions.
Many traditional refrigeration components are not designed to function under CO₂’s demanding conditions and may fail when exposed to its high operating pressures. Therefore, opting for robust and CO₂-compatible products is essential to ensure both safety and efficiency.
How we are supporting the shift to CO₂
One of our customers in the refrigeration industry approached us with a need for reliable CO₂ sensors that could withstand the unique pressures and temperature variations of a CO₂ system. Drawing on our knowledge of refrigeration technology, we developed a sensor solution tailored for CO₂ applications.
A standout feature of our CO₂ sensors is the extended cooling neck, that protects the electronic components from extreme heat and condensation. This cooling neck acts as a thermal barrier, shielding sensitive electronics and ensuring accurate, consistent sensor performance even in challenging conditions. This design not only improves sensor reliability but also extends the product’s lifespan, making it a cost-effective choice for companies using CO₂.
By choosing components designed to meet the demands of high-pressure, high-temperature applications, companies can ensure both regulatory compliance and operational efficiency.
When frost accumulates, it can block airflow, reduce system efficiency, and increase energy costs due to frequent, often unnecessary defrost cycles. Recognizing this issue, our team set out to develop a smarter solution: The Defrost Sensor.
Traditionally, refrigeration systems rely on timer-based defrosting, where defrost cycles are set to activate at regular intervals, regardless of actual frost levels. This system doesn't "know" whether frost has formed or not - it simply triggers defrost based on time alone. As a result, energy is often wasted on unnecessary defrost cycles, contributing to increased costs and reduced efficiency.
Our Defrost Sensor was designed specifically to address this problem by only defrosting when necessary. Using advanced technology, this sensor measures the difference between air and ice, allowing it to detect the actual presence of frost. When ice begins to form, the sensor triggers defrosting just as it’s needed, avoiding unnecessary cycles and saving energy.
For the Defrost Sensor to function effectively, correct installation is key. It should be placed where ice typically builds up on the evaporator. This positioning ensures accurate readings and optimal performance, making each defrost cycle as effective as possible.
The benefits of switching from timer-based to demand-based defrosting are clear. For instance, Arla, a major dairy company, implemented our Defrost Sensor and saw impressive results. They reduced their defrost cycles from 8 times a day to just once, leading to significant energy savings and improved system efficiency. This reduction in defrost frequency means not only less energy consumption but also a longer lifespan for the evaporator, as it undergoes less thermal stress.
How can you effectively control oil levels and protect your compressors?
This question was first raised by a leading Danish company years ago, driven by a need for a better solution to protect refrigeration systems. Together with our development team, we designed a sensor that can do exactly that.
The result was our HBOC Sensor, which has been offering built-in oil management functionalities that go far beyond the capabilities of a traditional oil sensor for close to 30 years.
But what makes this sensor so smart?
It registers the oil in the separator and ensures it is properly returned to the compressors, keeping your system running smoothly and avoiding the risk of your compressors burning out due to a lack of oil.
Like the rest of our product range, the HBOC Sensor has a robust design built to withstand the demanding conditions of industrial refrigeration. That means no moving parts and a split design to ensure easy maintenance so the system can continue to run with as little disturbance as possible.
However, that is not all. It can also differentiate between oil and ammonia, ensuring safe oil return and preventing contamination.
Our HBOC Sensor allows us to help enhance safety and operational efficiency by centralizing control and allowing the sensor to manage the oil valve directly.
With rising energy costs and sustainability goals in focus, more companies prioritize smart solutions to maximize performance. And we’re proud to support this shift with our innovative sensor technology, designed to deliver significant energy savings and operational benefits.
Did you know? Over a decade ago, we introduced our Vapor Quality Sensor, specifically designed to help refrigeration systems operate at peak efficiency, delivering substantial energy savings.
But what exactly does this product do?
This product allows you to maximize the performance of your evaporator by providing a direct, real-time measurement of the evaporation process. It offers precise insights into what’s happening within the pipes, functioning like an electronic sight glass to monitor liquid levels accurately.
Here’s how it makes a difference:
• In pump-circulated systems, we can control the circulation rate down to 1-1,5 CR to stay in optimal range, resulting in at least 20% energy savings.
• In DX systems, our sensors increase performance by reducing superheating and power consumption - leading to energy savings of up to 20% during full load and 50% during part load.
Our products are designed with the needs of the industrial refrigeration industry at their core. Our Liquid Level Sensor is a great example of this commitment. It was developed to address common issues that lead to costly system breakdowns - specifically oil buildup in the standpipe and liquid leaks into the electronics.
Our smart split design allows easy separation of the mechanical and electronic components, making troubleshooting and servicing more straightforward. Plus, we recommend a slight incline in the standpipe to ensure effective oil drainage, further increasing system uptime and reliability.
This level of detail and consideration is what we bring to every solution, helping our customers keep operations smooth and efficient.
