Case Study: Intelligent Retrofit & Energy Monitoring at Haskell & Co
30 June 2025
Client Overview
Haskell & Co, a Nottinghamshire-based refrigeration contractor, operates a critical facility providing cold storage and blast freezing services to a variety of clients in the food supply chain. Known for their dependable service and robust operational standards, Haskells’ Nottinghamshire site plays a key role in ensuring products remain in prime condition throughout the cold chain.
Despite their strong mechanical foundation, much of their plant infrastructure was legacy equipment—originally well-engineered but now hindered by outdated controls and an increasing lack of visibility into performance. Recognising the need to bring their systems into the modern era, Haskells approached Ultra Refrigeration Ltd to develop a phased control upgrade solution that could be implemented without compromising service.
The Challenge
At the heart of Haskells’ plant were four Sabroe two-stage compressors operating with open-flash intercooling and mechanical oil cooling. These machines, though mechanically sound, were controlled by legacy panels that offered no remote access, little to no alarm functionality, and relied on daily manual inspection of gauges and temperature readouts. Compressors had to be manually started and stopped, and any performance issues could go unnoticed until a failure occurred.
The control system’s inefficiency was compounded by rising energy costs and tightening environmental expectations. The business needed improved reliability, better diagnostics, and detailed energy performance data—but the challenge was to deliver all of this without shutting down operations or disrupting service to customers.
Ultra’s Retrofit Solution
Ultra Refrigeration responded with a carefully planned upgrade strategy centred on the RDM control ecosystem, tailored with Ultra’s highly customised software—designed specifically for this site and application.
Condenser Control Modernisation
The first step focused on condenser fan control. Ultra installed an RDM PR0680TDB controller featuring pressure-based step control with ambient tracking and predictive control logic. This brought immediate improvements in head pressure stability. A speed output channel, integrated within the controller, also provides future compatibility for EC fan upgrades.
BeforeAfter
Compressor Control and System Intelligence
Each of the three operational Sabroe compressors was progressively integrated into the new control system, using an RDM PR0650TDB plant controller expanded with PR0661 modules. Ultra’s software orchestrates compressor rotation based on run hours and fault tolerance, ensuring only two compressors are in use at any one time, while the fourth has been decommissioned and retained for spare parts.
This upgrade introduced a suite of new monitoring points, alarm conditions, and full automation—replacing the previous manual control setup and removing the need for the array of unreliable mechanical pressure switches, gauges, relays, timers and step controllers.
Remote Access and System Visibility
The inclusion of an RDM PR0680MDM mini data manager brought secure remote access to the entire plant as well as integrating the existing leak detection systems. Haskells staff can now view real-time system performance and alarms from any internet-connected device via a graphical user interface, drastically improving operational oversight.
Power & Energy Monitoring Integration
To further enhance system intelligence, Ultra is installing kWh metering on each compressor to support fault tracking. Discrepancies in power consumption between units can indicate emerging mechanical issues, such as valve wear or internal inefficiencies.
Additionally, plant-wide kWh monitoring is being added to enable full energy cost analysis. The TDB software automatically calculates the energy cost of each refrigeration cycle using user-defined peak and off-peak electricity tariffs. This enables true cost-per-cycle reporting, helping Haskells make data-driven decisions around energy usage and load management.
Results
The new controls have already enabled the identification and correction of several hidden faults—such as faulty valves—leading to immediate improvements in system stability. Automation of daily routines has freed up operational staff and reduced the potential for human error.
With a powerful monitoring interface now in place and granular energy insights on the horizon, Haskells is positioned to gain long-term benefits in system reliability, efficiency, and operational cost control.
Next Steps
Building on this success, Haskells has authorised the next phase of works: upgrading the evaporator controls and introducing stepper expansion valves. These upgrades will further optimise temperature control and system efficiency, bringing the plant closer to full automation and advanced energy management.
Conclusion
Ultra’s solution at Haskells & Co illustrates the value of combining proven mechanical systems with modern, intelligent control platforms. By leveraging RDM hardware and Ultra’s bespoke software expertise, Haskells has transformed an ageing refrigeration plant into a smart, reliable, and energy-aware facility—laying the foundation for future scalability and sustainability.
