Star Refrigeration repaired cold store for The Ice Co Storage and Logistics

Platon Tvardovski

Star Refrigeration’s Leeds branch have successfully replaced an unused cold store plant for The Ice Co Storage and Logistics in Newark in order to be leased to a third party.

Noting that the original Cold store plant operated with a R404A refrigerant and an F-gas, currently being phased down by new regulations, Star concluded that in order to reinstate operations, the plant would require not only a controls upgrade and a condenser replacement, but also a refrigerant conversion to allow for the operation of the plant in the medium term.These costs would have amounted to roughly the same as replacing the existing common plant with all new facilities and it was agreed that comprehensive replacement represented the best option.

The supply, installation and commissioning of the new plant was carried out as a branch contract through Star’s Leeds branch. The new plant took the form of two DX R449A condensing unit plants, both of which serve a single ceiling-mounted evaporator within the Cold store. Both units operate at 36kW, which represents 65% of the maximum design duty, affording a solution which combines performance with resiliency.

Star took advantage of an existing concrete plinth situated at ground level directly behind the internal evaporators to install the condensing units, while two networks of interconnecting pipework were run up the outside of the building to reach the roof void above the evaporators. This achieved a practical solution which minimised installation time, expense and effort.

Star also prioritised energy-efficiency in this project. By incorporating the same electronic expansion valves, EC condenser fans (known to reduce energy consumption by up to 20% on their own) and a skip-defrost function, Star were able to guarantee optimal energy consumption.

Furthermore, The Ice Co Storage and Logistics is one of many businesses to benefit from Star’s award-winning refrigeration energy management system Ethos, which scooped Refrigeration Product of the Year at the 2018 National ACR & Heat Pump Awards.

For the same price as a basic refurbishment and upgrade of the original R404A plant, the client obtained a complete replacement of the Cold store, which now meets all current regulations, enjoys increased energy-efficiency and represents an additional avenue of revenue through a third-party lease. What’s more, the project included a comprehensive maintenance contract for the first 12 months of the plant’s operation, ensuring it’s not only a reliable and lucrative asset today, but safeguarded by Star’s ongoing relationship with the company for the future.

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