In the world of business, true innovation often requires a leap of faith. It’s not enough to follow the well-trodden path; real success frequently demands the courage to step into the unknown, to take risks, and to embrace change with passion and conviction. This is particularly true in industries like cold storage, where traditional methods have long dominated the landscape.
However, as the demands for energy efficiency, environmental responsibility, and operational flexibility grow, there is an increasing need for solutions that break the mould. Enter i-Air—a transformative approach to cold store cooling that is poised to revolutionise the way we think about refrigeration
The Courage to Innovate
Innovation in business is never without its risks, but it is precisely this willingness to challenge the status quo that can lead to significant breakthroughs. For logistics companies like Dale Brothers, stepping into the unknown with i-Air represented a bold move. Traditionally focused on refrigerated logistics, they were venturing into new territory by building their first refrigerated warehouse. This required a shift in their operational model, one that necessitated careful consideration and a commitment to embracing new technology.
i-Air isn’t just another refrigeration system; it’s a different approach altogether. While the system has been tried and tested in retail environments, its potential in cold store operations is even greater. Retail settings often require frequent changes in layout and use of display cases, which need to be carefully planned with ducted air systems. In contrast, cold stores, with their more stable environments and consistent temperature requirements, are an ideal fit for i-Air’s capabilities. This system offers a level of efficiency and environmental benefit that traditional refrigeration methods struggle to match.
i-Air: A Game-Changer for Cold Store Cooling
At its core, i-Air comprises a remote refrigeration system paired with Air Handling Units (AHUs) that deliver cooled air into the cold store via ductwork. One of the standout features of i-Air is its ability to utilise free-cooling—using outside air to refrigerate the store when external conditions are favourable. This not only maintains optimal storage conditions but also leads to substantial energy savings, with potential reductions in energy usage of up to 70% compared to many existing standard systems.
The benefits of i-Air extend far beyond energy savings:
- Real-Time Monitoring and Analysis: i-Air continuously tracks key parameters, providing real-time data on the cold store’s condition. This constant monitoring ensures that the system operates at peak efficiency and allows for immediate adjustments when needed.
- Energy Optimisation: By analysing both internal and external conditions, i-Air optimises energy use, deciding whether to recirculate or expel air based on what is most efficient. This approach not only saves energy but also maintains the necessary temperature and humidity levels for optimal storage.
- Automated Control Adjustments: i-Air automates many aspects of the refrigeration process, such as defrost cycles, compressor usage, and valve settings. This reduces the need for manual intervention and minimises the risk of human error, ensuring that the system operates smoothly.
- Environmentally Friendly Refrigerant: i-Air uses R290, a refrigerant with a low Global Warming Potential (GWP=3), making it a sustainable choice for large-scale refrigeration needs. This contributes to reducing the overall carbon footprint of the cold store.
- Low Refrigerant Charge: The system’s design requires a minimal refrigerant charge, which lowers the risk of leaks and further reduces its environmental impact. This feature also enhances the safety and efficiency of the system.
- Ease of Maintenance: i-Air’s design eliminates the need for high-mounted evaporators, which are typically difficult to access. This makes maintenance tasks simpler, safer, and less time-consuming, as technicians no longer need to enter the cold store to perform routine checks or repairs.
- Increased Storage Space: By eliminating the need for evaporators within the cold store, i-Air frees up valuable space that can be used for additional racking and storage of goods.
Market Sectors Benefiting from i-Air
The versatility of i-Air makes it suitable for a range of industries, each benefiting in different ways:
- Retail: Retail environments benefit from better temperature stability, increased merchandising space, and a more reliable cooling system that doesn’t require emptying cabinets for repairs. Additionally, i-Air’s design eliminates the need for cabinet dividers and prevents water leaks, enhancing the overall shopping experience. Read more.
- Food Manufacturing: i-Air ensures consistent temperature control, which is critical for maintaining the quality and safety of food products during processing and storage.
- Logistics & Distribution: For logistics companies, i-Air offers a reliable and energy-efficient solution for managing large cold stores, ensuring that goods are kept at the right temperature throughout the supply chain.
- Data-centres and Environmental Testing Chambers: These sectors benefit from i-Air’s ability to maintain precise environmental conditions, crucial for the sensitive equipment and processes housed within these facilities.
i-Air vs. Traditional Systems: A Comparative Analysis
When comparing i-Air to even the next-best ‘traditional’ refrigeration systems, the differences are stark. Our analysis for Dale Brothers compared a ‘reference’ cold store system with leading-edge equipment and controls running on various refrigerants, including R407F, R449A, CO2, and i-Air with R290. The ‘reference’ cold store measures 55 meters long by 20 meters wide by 6 meters high (6,600 cubic metres) with a system lifetime expectancy of 20 years. The selected location, which determines the ambient temperature, is assumed to be Birmingham.
| Reference coldstore system | R407F | R449A | CO2 | i-Air using R290 | |
|---|---|---|---|---|---|
| Total annual energy consumption (kWh) | 51,965 | 57,460 | 54,301 | 63,959 | 45,783 |
| Yearly energy savings (kWh) | – | -5,495 | -2,336 | -11,994 | 6,183 |
| Yearly energy savings (%) | – | -10.6% | -4.5% | -23.1% | 11.9% |
- The figures are compelling:
- i-Air’s total annual energy consumption is 45,783 kWh, compared to 51,965 kWh for the reference system, and is significantly lower than the other systems.
- This translates to annual energy savings of 11.9% compared to the next-best ‘reference’ system.
- Taking into account the initial investment cost and the present value of energy and maintenance costs, the i-Air system is calculated to have a substantially lower lifecycle cost than the other systems, and a payback time of around 4.5 years.
- In terms of Net Zero targets, i-Air boasts the lowest CO2 lifetime emissions, thanks to its small charge of R290 low GWP refrigerant.
These figures highlight the financial and environmental benefits of adopting i-Air, making it a smart investment for companies looking to reduce costs and minimise their carbon footprint.
Conclusion: A Step Towards the Future of Cold Storage
i-Air represents a bold new direction for the cold storage industry, combining cutting-edge technology with a deep commitment to sustainability. For businesses like Dale Brothers, choosing i-Air was not just about improving efficiency—it was about taking a step towards the future. In an industry where tradition often dictates choices, embracing innovation requires both courage and vision.
By delivering significant energy savings, reducing environmental impact, and offering unparalleled flexibility, i-Air is setting a new standard for cold store refrigeration. As more companies recognise the benefits of this transformative system, i-Air is poised to become the ‘go-to’ solution for cold storage facilities across various sectors. In the end, those who are willing to take risks and embrace change will not only stand out in the marketplace but will also contribute to a more sustainable and efficient future for the industry.
If you would like to discuss aspects of your existing refrigeration equipment, or want to talk about a new project, please get in touch by contacting us or calling us on +44 (0) 330 2232404.
