ENERGY SAVING
positioning. In a fan pack, all components are designed to fi t and work with each other to achieve the highest airfl ow rate for an imposed system impedance with minimum energy consumption. Now, let’s break down the importance of each element and the critical aspects for their maximum effi ciency: ■Motor technology: using EC (electronically commutated) technology represents a watershed, because it allows fan speed adjustment according to demand. Thanks to the embedded electronic control, it can reach output effi ciency levels of 70%, whilst shaded pole technology reaches only 30%. This technological advancement alone can more than double the effi ciency of the air movement subsystem.
■Blade design: It is an equally crucial and complex science that balances multiple parameters. The most critical aspects include aerodynamic profi le, angle of attack, pitch, hub-to-tip ratio (the relation between the diameters of the fan’s centre and of the blade’s tips), and number of blades. Blades with optimised aerodynamic profi les reduce movement resist- ance, increasing effi ciency. The blade’s angle determines how much force is applied to the air in each rotation – excessively aggressive angles move more air but require more power and generate turbulence; overly gentle angles are ineffi cient. The number of blades directly aff ects air-moving capacity and noise levels. There must always be a balance between fl ow rate and drag, with a sweet spot equilibrating these eff ects. Intelligent aerodynamic design can generate such substantial gains without simply increasing motor power. It is possible to achieve improvements of up to 40% in airfl ow with an optimum balance of all variables. The imperative is to consume less energy whilst delivering the same airfl ow rate, or to provide a higher level of airfl ow whilst maintaining the same power consumption level.
■Shroud: The shroud completes the air movement system, directing airfl ow precisely and whilst minimising aerody- namic losses. This fan part must be designed to maximise air capture and direct fl ow through the heat exchanger with minimal energy loss. The physical integration between motor, blade, and shroud creates a solution that functions as a single system, not as independent parts. To achieve optimal design, extensive Computational Fluid Dynamics (CFD) simulations are employed to optimise every detail, alongside prototyping and experimental evaluation in wind tunnels. Considering the extreme operating conditions involved (high temperatures and humidity), material selection also matters, such as employing polymers with strength-to-weight ratios that maintain their properties in all situations. Finally, proper positioning and installation are fundamental since a well-de- signed fan pack, if poorly installed, will signifi cantly compro- mise performance.
Collateral positive impacts Proper air movement generates value across multiple dimensions that extend beyond direct energy savings. We can list a few: ■Product conservation: Uniform air movement eliminates hot spots within the refrigeration equipment, ensuring all products are maintained at the ideal temperature. In food re-
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tail, this means less waste due to deterioration, greater shelf life for sensitive products, and better consumer experience. For medical and pharmaceutical applications, it is a matter of regulatory compliance and safety.
■ Frame breaking opportunities: Optimised air movement allows the use of more compact heat exchangers without capacity loss, providing potential for a 5-10% increase in practical internal volume of equipment. This is valuable for retailers wishing to maximise product display space without increasing equipment footprint.
■ Durability and reliability: Adequate air movement reduces thermal stress on all system components. Compressors oper- ating at lower condensing temperatures may have extended service life. Electronic products exposed to less heat tend to degrade more slowly. This translates into a lower total cost of ownership (TCO).
■ User experience: Effi cient air movement reduces fan speed and noise, creating a better shopping experience in retail and more comfort in spaces where commercial refrigerators are close to people for long periods of time (mini-bars in hotels, display cases in offi ces).
Air movement and decarbonisation Decarbonisation is one of the most critical drivers in the refrigeration industry today, and air movement improvement is part of the path to get there, reducing energy consumption. It reinforces a fundamental principle: energy savings drive sustainability.
Since most global electricity still comes from fossil sources, each kilowatt-hour avoided means fewer CO2
emissions.
Even with renewable energy, reducing demand decreases infrastructure needs, optimises natural resources consumption, and increases system resilience.
The path to decarbonisation does not depend on
revolutionary technologies, but on systematic optimisation of each component. Air movement-related components, once overlooked, now also represent a signifi cant opportunity for meaningful progress towards a more sustainable future.
www.acr-news.com • January 2026 27
'The proper integration between
them is what diff erentiates a premium solution from a conventional one, delivering maximum airfl ow whilst minimising energy
consumption.'
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