SUPERMARKET REFRIGERATION


The hidden complexity of distribution centres


From deep-freeze zones to ambient corridors, the cooling infrastructure of supermarket distribution centres must adapt to varied loads, fl uctuating external conditions, and constant operational churn, making it one of the most technically complex and mission-critical elements of the supply chain. In this article, David Bostock, divisional director of Integral Cooling Tech, explores the intricate demands of temperature-controlled environments, where precision refrigeration ensures product integrity, energy effi ciency, and regulatory compliance.


S David Bostock


"Insulation detailing, vapour


barriers, and freezer fl oor heating all contribute to long-term resilience."


Supermarket distribution centres are among the most technically demanding environments in the food supply chain. These facilities combine the scale of industrial


refrigeration with the pace of logistics, running 24/7 to keep the cold chain intact. To the public, they are invisible. But for engineers and facilities teams, they are complex assets that must run continuously to keep food moving safely through the supply chain.


Automation has brought huge effi ciencies to warehousing.


However, it has also raised the bar for the supporting infrastructure. Distribution centres now need refrigeration systems that can adapt to changing product ranges, handle seasonal peaks and meet sustainability targets without compromising food safety.


Why distribution centres matter Downtime in a distribution centre is unforgiving. A short outage in frozen storage can destroy stock, while failures in chilled areas risk food safety breaches and costly waste. The damage for retailers extends beyond lost goods, where disrupted deliveries can ripple through the supply chain and erode customer confi dence. Seasonal surges make the challenge even bigger. At Christmas or in summer heatwaves, throughput can double. Systems must be designed with enough capacity and resilience to absorb the extra load while still operating effi ciently. That’s why these sites cannot be treated as standard


warehouses. They are engineered assets, with their performance depending on careful integration of refrigeration, ventilation, power and automation. Most supermarket distribution centres bring together


diff erent regimes under one roof: chilled, frozen, produce and ambient. Each has its own demands. Chilled zones require tight control with little tolerance for fl uctuations. Frozen storage needs robust defrost strategies and slab protection


18 October 2025 • www.acr-news.com


to avoid frost heave. Produce rooms often call for humidity management to preserve freshness. Separating these areas is a discipline in itself. Thermal barriers, door management, airlocks and vapour control are all part of maintaining effi ciency and preventing cross- contamination.


Refrigeration choices Technology selection depends on the scale and priorities of the operator. Ammonia remains a highly effi cient option for large central plants, provided safety and operational expertise are in place. CO₂ transcritical systems are now in widespread use and often enhanced with parallel compression, ejectors or adiabatic cooling to improve performance in warmer conditions. In some contexts, low-GWP HFO blends still have a role, particularly in retrofi ts where capital budgets are tight. The common factor is the need to balance effi ciency,


safety, compliance and lifecycle cost. Controls often make the biggest diff erence: fl oating suction and condensing pressures, variable speed drives (VSDs) and demand-based defrosting can all deliver signifi cant savings when properly applied. At a supermarket’s distribution centre, for example, we retrofi tted an ambient store, converting it into a chocolate chamber designed to keep products stable at 2°C to 4°C, since chocolate often falls outside standard temperature ranges. The installation benefi ted from fans with variable speed drives and the latest valve technologies – all of which add signifi cant energy savings compared to standard installation – demonstrating how thoughtful retrofi ts can deliver step- changes in effi ciency without disrupting supply.


Monitoring and maintenance Distribution centres cannot aff ord a reactive approach. Intelligent systems are moving us into an era of fully predictive and condition-based maintenance, using sensor data to highlight developing issues before they interrupt operations.


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