BUILDING & FACILITIES MANAGEMENT H
eating, ventilation, and air conditioning (HVAC) systems are integral to modern industrial environments. From food processing plants and manufacturing facilities to logistics hubs and data centres, HVAC systems underpin productivity
by regulating temperature, reducing humidity, filtering air, and protecting both people and equipment. Without them, many industrial operations would grind to a halt. But while HVAC systems are essential, they are not without risk. The refrigerants that make them effective can become hazardous when leaks occur. Beyond the immediate dangers to people, refrigerant loss drives up energy consumption, reduces system efficiency, accelerates wear on equipment, and contributes to climate change. With tightening F-gas regulations across the UK, the case for investment in gas detection is stronger than ever. Smart detection systems can help industrial operators reduce emissions, contain operational costs, and meet increasingly strict compliance requirements.
BACKBONE OF INDUSTRIAL OPERATIONS In industrial environments, HVAC systems are far more than a comfort feature. In food and beverage production, they ensure safe storage and handling of perishable goods by maintaining cold chain integrity, while they provide precise climate control that protects sensitive processes and prevents hazardous reactions in chemical and pharmaceutical plants.
Warehouses and logistics facilities also rely on HVAC systems to protect stock, while data centres depend on them to maintain optimal operating temperatures for servers and electrical equipment. Even in heavy manufacturing, stable air quality reduces dust and particulates that can harm workers and machinery alike.
Across all these settings, HVAC systems are high- energy assets, often running continuously and consuming significant electricity. A failure or undetected leak not only threatens operational continuity but also risks reputational and financial damage.
HIDDEN DANGERS OF REFRIGERANT LEAKS Industrial HVAC systems typically use fluorinated refrigerants, many of which are colourless and odourless. Leaks often go unnoticed until staff begin experiencing symptoms or the system begins underperforming. Studies suggest that around 60 per cent of leaked gas escapes before it is detected. The immediate safety risks are serious. Inhaling leaked refrigerants can cause dizziness, headaches, respiratory issues, and skin or eye irritation. In high concentrations, leaks may lead to unconsciousness or fatal asphyxiation. Additionally, some refrigerants, such as propane (R-290), are flammable, raising the risk of fire or explosion in already high-risk industrial settings. The financial cost is also significant. The Carbon Trust estimates an average refrigerant leakage rate of 20 per cent per year in UK systems, equating to an 11 per cent reduction in efficiency. For energy- intensive industries, that translates into thousands of pounds in wasted energy each year. Finally, there is the environmental impact to consider. Hydrofluorocarbons (HFCs) are climate super pollutants, with a global warming
GAS DETECTION: SAFEGUARDING INDUSTRIAL OPERATIONS AGAINST HIDDEN RISKS
For industry leaders seeking to balance operational resilience with sustainability and compliance, investing in gas detection is no longer optional, but essential. Shaun Evers, managing director of Stonegate Instruments, explains.
potential thousands of times greater than CO₂. When released, they persist in the atmosphere for decades, intensifying climate change and contributing to ozone depletion.
RAISING THE COMPLIANCE BAR
Recognising these risks, regulators have imposed stringent requirements on the use of fluorinated gases. Since January 2020, refrigerants with a global warming potential (GWP) above 2,500 have been banned for servicing or refilling large refrigeration systems in the UK. Leak detection and monitoring are now mandatory depending on system size. Equipment containing five tonnes of CO₂ equivalent or more must be checked annually. Systems with 50 tonnes require checks every six months, while those above 500 tonnes must be inspected quarterly and fitted with automatic leak detection systems. Penalties for non-compliance are significant. The UK’s Environment Agency can issue fines of up to £200,000 for breaches such as failing to carry out checks, not installing mandatory detection equipment, or continuing to operate with banned refrigerants. For industrial operators, the consequences extend
20 AUTUMN 2025 | INDUSTRIAL COMPLIANCE
beyond fines – non-compliance can disrupt operations, delay projects, and harm customer confidence. In sectors where margins are tight and downtime is costly, the reputational and financial consequences of non-compliance can be just as damaging as regulatory penalties.
Regulation is also evolving rapidly. The revised EU F-gas Regulation agreed in 2024 sets out a phased approach to reduce and eventually eliminate the use of HFCs, culminating in a total phase-out by 2050. The UK is continuously reviewing its own framework, which is expected to align closely with EU objectives.
For industry, this means the regulatory trajectory is clear: high-GWP refrigerants will be phased out, monitoring obligations will remain strict, and investment in detection technology is no longer optional. Companies that plan ahead will reduce compliance risks, cut costs, and gain competitive advantage as low-carbon practices become a standard requirement in supply chains.
SMART GAS DETECTION
Modern gas detection technology has advanced considerably in recent years, making
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