SUPERMARKET REFRIGERATION


Engineers track parameters such as suction and discharge pressures, superheat, compressor effi ciency, and defrost cycles, comparing performance against benchmarks. Centralised monitoring across multiple sites adds further value, allowing operators to compare performance, spot anomalies and target investment where it delivers the greatest benefi t. Facilities managers are increasingly using this data to bridge the gap between engineering systems and business outcomes.


Building resilience Reliability is as important as effi ciency. Distribution centres depend on layered redundancy: dual compressor packs or parallel systems to cover partial load, backup generators to maintain supply, and controls designed to default to safe operation if a fault occurs. Physical infrastructure plays its part too. Insulation detailing, vapour barriers, and freezer fl oor heating all contribute to long-term resilience. These measures are rarely visible but make the diff erence between a plant that runs for decades and one that fails early.


Working with automation As warehouses become more automated, refrigeration engineers must work closely with systems integrators and automation suppliers. Conveyor systems running through cold zones create heat ingress and airfl ow disruption that the cooling plant must account for. High-bay storage requires stratifi cation control to maintain uniform temperatures from top to bottom. Early collaboration avoids confl icts and ensures the building operates as a single integrated system rather than a collection of separate technologies.


Designing energy-effi cient systems The complexity of distribution centres extends beyond refrigeration. Lighting, ventilation and air management also make a diff erence to performance. Many operators are now fi tting high-effi ciency LEDs linked to occupancy sensors, ensuring illumination is only provided where and when it’s needed. Ventilation systems, particularly around docks and ambient zones, are being designed with air curtains and rapid doors to minimise unwanted heat ingress.


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Even simple measures can deliver results. At the UK distribution centre of a European supermarket chain, we installed proximity sensors to monitor how long cold store doors were left open. By providing weekly analytics to site managers, the system drove a reduction in prolonged door openings, cutting waste, improving compliance and reducing emergency callouts. It highlights how operational behaviour, as much as plant effi ciency, can unlock substantial savings. Cold chain operations are energy-intensive, and supermarkets are under pressure to cut both direct and indirect emissions. Refrigerant choice and leak prevention reduce direct emissions, while energy strategies bring down the indirect impact. Techniques such as fl oating head pressure, waste heat


recovery and integration with renewables are increasingly common. Some operators are starting to view refrigeration plant not just as a load but as a source of energy, reclaiming waste heat for ventilation or hot water. With supermarkets facing ambitious Net Zero targets, distribution centres are becoming testbeds for these innovations.


What operators should prioritise Those responsible for cold chain management must focus on designing systems as a whole, rather than piecemeal upgrades. Choosing refrigerants with an eye on long-term compliance is crucial. This means building in resilience and redundancy from the outset. Embed sustainability into every stage of the process, while investing in predictive maintenance to avoid downtime and extend asset life. These principles reduce risk, control costs and keep the cold chain intact. The supermarket cold chain is often taken for granted, but those working behind the scenes know how much depends on these facilities. Distribution centres are not just storage sheds – they are complex, highly engineered assets that underpin food security and customer trust. Behind every automated conveyor and robotic picker lies an invisible network of cooling systems, backup power and smart controls, all working together to ensure that products reach the shelves in peak condition. For retailers, the message must be to treat distribution centres as strategic assets and not background infrastructure. This is the key to resilience, effi ciency and sustainability.


"Distribution centres now need refrigeration systems that can adapt to changing product


ranges, handle seasonal peaks


and meet


sustainability targets without


compromising food safety."


www.acr-news.com • October 2025 19


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