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“Energy-efficient refrigeration and cold-chain crucial to maintain food quality”
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Monday, 07 October, 2024, 08 : 00 AM [IST]
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 Johnson Controls enhances energy-efficient refrigeration and cold-chain solutions in the food sector, ensuring product quality while lowering operational costs. Our expertise in industrial refrigeration addresses the increasing demands for food safety and sustainability. We support the rising need for ready meals and frozen produce, optimising efficiency throughout the entire plant lifecycle, said Prasad Sannagowder, director, sales: industrial refrigeration, Johnson Controls, India, in an email interaction with Nandita Vijayasimha. Excerpts:
Why are energy-efficient refrigeration systems becoming essential for competitiveness in India's food industrial sector?
In the face of the global climate emergency, India’s Net Zero ambitions and market forces are driving industries toward sustainable practices. Energy-efficient refrigeration systems play a crucial role in this shift, especially as cooling infrastructure significantly impacts greenhouse gas (GHG) emissions. Conventional refrigerants, like HFCs (hydrofluorocarbons), have a global warming potential (GWP) thousands of times greater than CO2. In fact, HFCs contribute to about 2% of global GHG emissions, which is substantial considering their widespread use in cooling systems. The Kigali Amendment and the India Cooling Action Plan (ICAP) have nudged industries toward adopting sustainable cooling technologies by phasing out harmful refrigerants like HFCs (hydrofluorocarbons), as they contribute to Greenhouse Gas (GHG) emissions. Furthermore, as global markets increasingly favour sustainable practices, Indian companies that invest in energy-efficient systems gain a competitive edge by attracting international investments and reducing operational costs. The industrial refrigeration market in India is expected to grow to US$38.85 billion by 2036, with a 4.9% CAGR, driven by sectors like food processing, pharmaceuticals and logistics.
Compared to 2011, when energy-efficient systems were still relatively niche, there has been a significant shift towards greener technologies, driven by regulatory pressures and rising energy costs. Reports suggest that the global market for energy-efficient HVAC and refrigeration systems is projected to grow at a CAGR of 11.2% between 2021 and 2028, therefore, to stay competitive, industries must embrace energy-efficient solutions as sustainability becomes key to long-term growth and market success.
How can refrigeration systems in food processing industry be adapted to meet India's stringent environmental regulations?
To meet India's stringent environmental regulations, refrigeration systems for the food processing industry must prioritise transitioning from high-GWP refrigerants like HFCs to natural alternatives such as CO2, ammonia, and hydrocarbons, under the Kigali Amendment, which mandates the phasing out of harmful refrigerants. Additionally, integrating energy-efficient technologies like variable speed drives (VSDs), smart controls, and heat recovery systems can significantly reduce energy consumption and emissions. For instance, Johnson Controls provides advanced industrial refrigeration solutions that help cold chain operators meet regulatory requirements. The Frick Low Charge Central System retains the operational efficiency and reliability of a central refrigeration system with the control precision of the Frick packaged remote distributed condensing (RDC) units. This configuration results in a total system ammonia charge of approximately 1.5-3 lbm/TR. Frick offers a complete low charge solution with compressors, evaporators, condensers, and controls.
Our systems incorporate VSDs, smart monitoring, and heat recovery units to enhance both energy efficiency and environmental performance. These innovations not only reduce operational costs but also ensure compliance with the Energy Conservation Building Code (ECBC) and frameworks given by the Bureau of Energy Efficiency (BEE). By adopting such advanced solutions, industries can comply with regulations while gaining a competitive edge in a market increasingly focused on sustainability.
How do innovations like variable speed drives and natural refrigerants help reduce energy consumption in refrigeration systems installed in food processing industries?
Variable Speed Drives (VSDs), including Variable Frequency Drives (VFDs), and natural refrigerants significantly reduce energy consumption in refrigeration systems at food processing plants. VSDs regulate the speed of the compressor motor based on real-time cooling demand, preventing excess energy use during low-load periods. VFDs, a type of VSD, achieve this by varying the frequency of the electrical supply to the motor, further optimising energy efficiency. The market for VFDs is projected to grow, reaching US$34.04 billion by 2029, with a CAGR of 5.02% from 2024 to 2029. The global trend reflects a collective commitment to exploring low global GWP alternatives and reducing greenhouse gas emissions. India’s Cooling Action Plan (ICAP) aligns with this goal despite a push for a faster approach. Due to global initiatives to phase out and reduce HCFCs and HFCs, ammonia is increasingly seen as the most suitable refrigerant for cold storage in the pharmaceutical, hospitality, and F&B industries.
What role do IoT-enabled smart controls play in real-time optimisation of refrigeration systems in the food processing sector?
IoT (Internet of Things)-enabled smart controls are integral to real-time optimisation of refrigeration systems, as they provide continuous monitoring and adaptive management. These controls use data from various sensors to automatically adjust refrigeration parameters in real-time, ensuring that the system operates at optimal efficiency at all times, with minimal human intervention. For example, they can modulate temperatures, detect equipment inefficiencies, and predict maintenance needs before failures occur. In sectors such as pharmaceuticals and food processing, where temperature consistency is crucial, IoT-based systems ensure compliance with strict standards while lowering operational costs. Additionally, the ability to monitor and control systems remotely increases flexibility and operational agility, essential for scaling cold chain operations across India.
What are the key challenges in adopting advanced refrigeration technologies in the food processing industry, such as high upfront costs and the need for skilled labour?
Adopting advanced refrigeration technologies in India comes with several challenges, such as power fluctuations and unreliable infrastructure alongside high upfront costs and a shortage of skilled labour. Although energy-efficient systems offer long-term savings, their initial costs are substantially higher than conventional systems, which can deter smaller players from making the transition. Additionally, the shift to natural refrigerants and complex technologies like IoT-enabled smart controls requires specialised knowledge, which is lacking in India's industrial workforce. Training programmes and upskilling initiatives are crucial to overcome this barrier. Government incentives, such as subsidies or conducive financing options for energy-efficient technology and skill development programmes, are helping to alleviate some of these challenges. However, without sufficient investment in both financial and human resources, large-scale adoption of advanced refrigeration technologies may be slow.
How is the growing demand for sustainable refrigeration solutions linked to India's food processing industry growth and expanding cold chain infrastructure?
The growing demand for sustainable refrigeration solutions in India is closely linked to the country’s industrial growth and expanding cold chain infrastructure. With rising urgency to meet environmental targets, companies are increasingly adopting technologies that minimise energy consumption and reduce emissions, ensuring long-term competitiveness while supporting India's sustainability goals. Johnson Controls India contributes significantly to this by offering advanced refrigeration systems that focus on energy efficiency, precise temperature control, and reliable performance. Our solutions, such as YORK YVWA Water-cooled Screw Chiller, Frick Screw Compressors, Heat Pumps, condensing units and evaporators, ensure efficient, scalable cooling for industries like food processing, and agriculture. This supports India's goals of reducing food wastage and increasing productivity while adhering to stringent environmental regulations, fostering both industrial growth and sustainability.
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