Cold storage

Most of a cold store’s bill is refrigeration, and so is most of the waste

In a typical food cold store, well over half of the electricity goes to the refrigeration plant — that plant rarely runs the way it was commissioned — we close that gap

−22 °C +41 °C Cold store Condenser Compressor Evaporator

Where a cold store spends its electricity

Typical split for a UAE chilled and frozen store — your own metering replaces these with real numbers

  • Compressors 55%
  • Condenser fans 12%
  • Evaporator fans 12%
  • Defrost 8%
  • Lighting, docks, other 13%

Per cent of site electricity, typical, illustrative Figures on this page are typical or illustrative ranges from our method, not audited results for a named site — your own baseline sets the real numbers

Follow the heat through the plant

The story of a cold store runs in a circle — here it is in the order the refrigerant meets each part

  1. Compressor - Infrared Compressor - Visible light Visible light Infrared
    01

    The compressor

    The largest single load — its start count and running pressure decide both the bill and its lifespan

  2. −18 °C +34 °C · 60% RH
    02

    The cold store

    Every door opening and failed seal lets warm, humid air in — that moisture becomes frost

  3. 46 °C 19.8 bar
    03

    The condenser

    Throws the heat outside — a dirty coil or a fixed setpoint makes the compressor work harder

  4. Oil separator - Infrared Oil separator - Visible light Visible light Infrared
    04

    Compressor sequencing

    Back at the compressors: which one runs, at what load, and how often it starts

  5. −28 °C runtime ↑
    05

    The evaporator

    Frost on the coil blocks heat pickup, so the plant runs longer to do the same job

  6. Suction pipework - Infrared Suction pipework - Visible light Visible light Infrared
    06

    The thermal camera

    Makes all of the above visible in one walk-round, with temperatures on every pixel

  7. 07

    Optimisation

    Corrections made one at a time, verified against the baseline

    Equipment and compressor tuning

One loop — four places to lose electricity

Every cold store is a loop — the evaporator pulls heat out of the room, the compressor lifts it to a higher pressure, the condenser throws it outside and the cycle starts again — each stage can waste energy in its own way

Expansion valve Refrigerant loop Heat in → Heat out Cold store the load 1 Compressor the heart 2 Condenser heat rejection 3 Evaporator heat pickup 4
  1. Cold store

    Product, panels and doors — heat leaks in through every gap

    Worn door seals, open dock doors and degraded panel joints let warm, humid air in — it turns to frost and the plant works harder all day

    What we do Thermal-camera envelope scan, seal repair, door interlocks

  2. Compressor

    Lifts refrigerant pressure — the biggest electrical load on site

    Poor sequencing means machines start and stop far more than needed, run partly loaded, or run against a higher pressure than the day requires

    What we do Staging and sequencing review, suction pressure reset, start counting

  3. Condenser

    Rejects heat to outdoor air — fans and coils set the head pressure

    Fouled coils, blocked airflow and a fixed head-pressure setpoint push compressor power up, most of all on cooler nights when it could be lower

    What we do Coil cleaning, fan control, floating head pressure

  4. Evaporator

    Coil and fans inside the room that absorb heat from the air

    Frost on the coil, timer-based defrost and fans that never slow down add heat to the room and then charge you to remove it

    What we do Demand-based defrost, fan control, superheat check

Typical sources of waste, and what we do about each

These are the findings we expect to meet in a UAE cold store — impact ranges are typical, not promised: your meters decide

Refrigerant leaks and frost on evaporators

What it looks like
Coils icing up, long runtimes, rising superheat, room slow to pull down
What we do
Leak check and charge verification, demand-based defrost, airflow check

Typical impact Capacity loss and extra runtime

Condenser fouling and air starvation

What it looks like
Head pressure and discharge temperature higher than they should be on a normal day
What we do
Coil cleaning, recirculation fix, fan staging

Typical impact Compressor power up with every degree of extra condensing temperature

Floating head pressure not used

What it looks like
Condensing pressure fixed all year, even on cool nights
What we do
Enable and tune ambient-following head pressure within manufacturer limits

Typical impact Roughly 2 to 3 per cent compressor power per degree of reduction

Compressor sequencing

What it looks like
Several machines part-loaded, frequent starts, cycling around the setpoint
What we do
Re-stage, widen the differential, add minimum run and off timers

Typical impact Fewer starts per hour, less wear

Door seals and dock infiltration

What it looks like
Frost around doors, fogging, warm patches in the thermal image
What we do
Seal repair, strip curtains, door interlocks, dock shelters

Typical impact Less latent load and less frost

Defrost schedules

What it looks like
Defrost on a fixed timer, heaters on after the coil is already clear
What we do
Move to demand or temperature termination and retime to off-peak

Typical impact Less heater energy, less heat dumped into the room

Loose terminals and hot connections

What it looks like
Connections running hotter than their neighbours on the thermal scan
What we do
Re-torque and repair at the next safe window, rescan to confirm

Typical impact Fire and unplanned-outage risk, plus resistive loss

Evaporator fans running at full speed

What it looks like
Fans at 100 per cent all day regardless of load
What we do
Temperature or demand-based fan control

Typical impact Fan power and fan heat both fall

Peak demand ignored

What it looks like
Pull-down, defrost and washdown all landing in the same hour
What we do
Re-time heavy loads outside the tariff peak

Typical impact Lower demand charges with no change in kWh

The camera shows what the walk-round misses

Pipework that looks fine in daylight can be shedding cold along its whole length — drag to see the difference

Thermal imaging survey
Suction pipework - Infrared Suction pipework - Visible light Visible light Infrared

The second benefit: assets that last longer

Energy gets the attention, but the mechanical outcome is often worth more — fewer starts, lower discharge temperature and a lower pressure ratio are what extend overhaul intervals

Fewer starts per hour

Proper staging and sequencing cut the stress cycles that wear contactors and bearings

Cooler discharge

Clean condensers and the right charge keep discharge temperature down

Lower pressure ratio

Floating head pressure lets the compressor work against less

Early warning

Thermal trending flags bearings and motors before they fail

A worked example

A 6,400 cubic metre frozen store with four compressors — illustrative figures, normalised for ambient temperature and stored volume

Typical paybackabout 4 months

Pharma and temperature-critical rooms

For validated cold rooms, product safety comes first — we never change anything inside a qualified range without your quality team’s approval, and use metering and thermography mainly to find waste in the plant around the room

Before After
Compressor starts per hour
9 3
Night baseload
100 69
Monthly consumption
100 69

Illustrative worked example — index, before = 100 (starts shown as counts)

Built for sites where refrigeration is the biggest line on the bill

The physics is the same everywhere — the load, the doors and the hours are not

  • Frozen food

    Blast freezers, low-temperature stores, dock areas

  • Dairy

    Process cooling, chilled water and CIP cycles

  • Meat and poultry

    Chilling, cutting halls and cold-chain distribution

  • Pharma cold rooms

    Validated 2 to 8 °C rooms where stability matters more than anything

  • Logistics hubs

    Multi-temperature warehouses with constant door traffic

Questions we hear first

Does the survey interrupt production?

No — metering uses clamp-on sensors and the thermal survey is contactless — in fact the plant has to be running under normal load for the readings to mean anything, so we plan around your shifts, including nights

How long does an assessment take?

One to three days on site depending on size, then five to seven working days to deliver the report — a permanent monitoring install takes about half a day

Do you sell equipment?

No — we are not tied to any manufacturer — many of the savings we find need no purchase at all: setpoints, schedules, control logic and seals — when hardware is justified we say so and you buy it from whoever you prefer

What if you find nothing worth fixing?

Then we tell you on the first call, before anyone visits — under Shared Savings the question never arises, because no verified saving means no fee

Is our data kept confidential?

Yes — your data stays on your dashboard and is never shared — we will sign an NDA before the first site visit if you ask

Which areas do you cover?

The whole UAE: Dubai, Abu Dhabi, Sharjah, Ajman, Ras Al Khaimah, Al Ain and Fujairah — we travel to site

Book a free assessment

Find out what your plant is wasting

One call of about twenty minutes — we work out whether there is enough on the table to justify a site visit, and tell you plainly if there is not

  • Free first assessment, no obligation
  • NDA before the visit if you want one
  • We sell no equipment, so findings are findings