In 2025, UK businesses are operating in an increasingly difficult financial environment. Rising employer costs, a higher National Living Wage, and unrelenting energy prices are eating into margins across the board. For energy-intensive sectors—especially those reliant on commercial refrigeration—profitability now hinges on efficiency (or self-power generation).
At Ultra Refrigeration, we know that the solution isn’t always a complete system replacement. It’s about upgrading intelligently—combining modern technology with existing infrastructure to unlock efficiency, reliability, and sustainability. In this blog – part of our Thrive in ’25 theme – we showcase some cost-effective technologies that deliver real impact, cutting refrigeration energy use by 20–40%, reducing maintenance burdens, and future-proofing operations.
The Case for Smarter Refrigeration
Before diving into specific technologies, it’s worth reiterating the urgency. UK companies are facing:
- Higher operational costs from taxation and regulation
- Energy prices that show little sign of falling
- Greater pressure to meet sustainability targets
- Economic uncertainty in world trade
That’s why efficiency isn’t just desirable—it’s essential.
Through intelligent automation, remote monitoring, and targeted upgrades, Ultra helps businesses navigate these challenges and thrive—without overhauling entire systems.
Technology 1: Electronic Expansion Valves (EEVs)
Traditional thermostatic expansion valves (TXVs) are limited in how precisely they can manage refrigerant flow. Electronic Expansion Valves offer dynamic, real-time control that dramatically improves efficiency.
Key Benefits:
- Reduced compressor power by lowering discharge pressure
- Improved cooling stability through dynamic superheat control
- Better temperature accuracy under varying load conditions
Industry-backed Results:
- Danfoss has reported 10–20% energy reductions when switching from TXVs to EEVs in supermarket refrigeration.
- Emerson case studies show 15–25% savings in commercial systems.
- ASHRAE research confirms double-digit efficiency gains with optimised superheat and discharge pressure.
- We have seen even greater improvements where both suction and discharge pressures are properly controlled and remain stable.
In short, EEVs offer a straightforward upgrade path with improved temperature stability, reduced compressor wear, better monitoring and diagnostics, more system control and less energy use.
Technology 2: EC Condenser Fan Motors
While often overlooked, condenser fan motors represent a major opportunity for energy savings. Upgrading from traditional AC motors to Electronically Commutated (EC) motors offers:
Advantages:
- Up to 30% energy savings through high-efficiency operation
- Variable-speed control for matching performance to demand
- Quieter operation and extended motor lifespan and reliability
Evidence from the field:
- A European Commission study confirmed up to 30% lower energy usage.
- ASHRAE and Emerson field tests back these figures, particularly in partial-load conditions—where most systems operate the majority of the time.

Whether part of a retrofit or new design, EC motors pay for themselves quickly in quieter operation, extended equipment life, enhanced reliability, and significantly lower energy bills.
Technology 3: Speed-Controlled Compressors (VFD)
Compressors are the heart of any refrigeration system—and also its largest energy consumer. Variable Frequency Drive (VFD) compressors introduce intelligent, load-responsive operation that can dramatically cut energy use and wear.
Core Benefits:
- Demand-based output gives precision cooling, reducing energy waste
- Smooth ramp-up lowers mechanical stress and extends life
- Stable suction pressure improves cooling consistency and performance
Data that supports the switch:
- U.S. Department of Energy studies show 15–35% energy savings with VFDs.
- Danfoss confirms superior performance in real-world partial-load applications.
- Ultra’s own project data shows improved reliability and reduced maintenance.
For businesses focused on long-term operational efficiency, VFD compressors are a smart investment, resulting in fine-tuned performance, lower energy bills, reduced system wear, and future-ready operations.
Technology 4: Programmable Logic Controllers (PLCs)

While the above technologies are impressive individually, their full potential is only realised through modern control systems. Enter the PLC—a flexible, intelligent automation platform that brings it all together.
What PLCs offer:
- Customisable logic tailored to your specific operation
- Real-time data monitoring and automated adjustments
- Integrated alarms for safety, early issue detection and response
Proven Impact:
- research shows a 17% reduction in compressor energy use and 77% less runtime for parallel units.
- A study in ECTI Transactions found up to 25% energy savings with PLC-based air conditioning systems.
- Many Ultra projects confirm more consistent system performance, longer equipment lifespan, and lower energy bills.
By automating responses to fluctuating conditions, PLCs ensure systems are always operating at peak efficiency, reducing waste, lowering energy consumption, and extending equipment life.
Putting It All Together: Real-World Upgrade in Action
One of the clearest demonstrations of Ultra’s approach came when a blast freezing company turned to us with an aging refrigeration system. Plagued by inefficiency, breakdowns, and the need for daily engineer checks—even at weekends—they needed a solution that didn’t involve full system replacement.
The issues:
- Old mechanical controls requiring constant adjustment
- No remote diagnostics or monitoring
- Frequent faults and high call-out costs
- Excessive energy usage
The Ultra solution:
- Internet-enabled control panels with custom software
- Modern sensors for live temperature and pressure data
- Automated diagnostics and real-time alerts
- Remote access for engineers and operators
The results:
- No more daily site visits—saving both time and money
- Faster fault identification and resolution
- Improved system efficiency and uptime
- Extended plant life, delaying costly replacement
All of this was achieved without interrupting operations—a vital point for businesses where continuous cooling is non-negotiable.
A System-Wide Strategy for Success
Each innovation—EEVs, EC motors, VFD compressors, and PLCs—delivers measurable benefits. But the real power lies in system integration.
By combining these technologies and linking them through intelligent controls, businesses can build a refrigeration system that:
- Operates efficiently in all conditions
- Learns and adapts over time
- Reduces manual intervention
- Cuts energy bills dramatically
- Supports sustainability and carbon-reduction goals
It’s a system that doesn’t just perform better—it thinks smarter.
Thrive in ’25 and Beyond
As the economic pressures of 2025 continue to mount, operational efficiency will separate the winners from the strugglers. At Ultra, we’re helping businesses not only survive but thrive by delivering tailored, high-impact refrigeration upgrades.
With energy costs unlikely to fall, sustainability regulations tightening, and wage bills rising, now is the time to act. Whether you’re running outdated systems or simply want to stay ahead of the curve, our design engineers are ready to help you explore your options.
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 emailing us today at info@ultraref.co.uk or calling us on +44 (0) 330 2232404.