Food processors need to act now on R22 issue
13 April 2010
New legislation banning the use of virgin R22 gas, which is widely used in food process and storage applications, could cause a headache for unwary food processors that do not plan the switchover process carefully.
While a total ban on the gas does not come into force until the end of 2014 – allowing the use of recycled gas for the time being - the food industry needs to act now, according to Nick Morley, Technical Support Engineer at Aggreko, the world leader in temporary power and temperature control systems.It is one thing to know about the new EU rules banning the use of virgin R22 gas in chiller equipment - but agreeing on what to do to replace it is another matter altogether. The ban on virgin R22 came in on 31st December 2009, but many businesses have still not decided on an alternative plan of action.
There are three options open to food companies when it comes to keeping on the right side of the new ozone and F-gas regulations (EC 2037/2000 and EC842/2006 respectively). The first option is to replace the whole plant or substantial elements of the process, looking to utilise the latest technology to improve efficiency and minimise the quantities of HFCs used to replace the R22 system (and hence make compliance to the F-Gas Regulations easier). The obvious issue with this option is the significant capital cost and the timescale to implement such a plan.
The second, more popular option we are seeing is the modification of existing plant to use a new refrigerant in place of R22. While this is usually a quick and relatively inexpensive option, which can be fitted in with service schedules, using ‘drop-in’ replacements can decrease plant efficiency, reduce cooling capability and cause reliability issues. Also, the existing plant age can mean this is only a stop-gap before new and more efficient equipment needs to be installed.
The third option is to do nothing, using the existing plant with recycled HCFCs. While this appears to be the preference for many food processors, perhaps driven by lack of available cash due to the recession, this is simply delaying the inevitable until the end of 2014, when measures will have to be taken. In the meantime, businesses could be faced with a decrease in plant efficiency as well as difficulties in getting hold of replacement gasses. Inevitably, we have seen the availability of recycled R22 fall in recent months due to a spike in demand. This has led to the cost more than tripling between 2009 and 2010. This is a trend that is likely to continue.
Whatever course of action food processors take to deal with the R22 issue, one thing is clear - careful planning is vital if an efficient and smooth transition from one refrigerant to another is to be achieved. This should take into account all of the options and address issues such as contingency planning, availability of replacement gasses, new equipment, seals, valves and potential temporary cooling solutions. Reduced plant efficiencies, less effective chillers and even the risk of unplanned downtime could all be scenarios created by poor planning surrounding the phase out of R22.
Food processors could be missing opportunities by not considering the positive role that temporary chillers can bring by acting as a vital stop-gap while a more permanent solution is implemented. This approach can also be part of the wider solution during the re-gas process or during warmer summer periods when a top-up KW facility can be used to maintain ambient temperatures.
For those that have not yet grasped the nettle and formulated a strategy to deal with the phasing out of R22, time is short. DEFRA, the government body will soon be tightening its grip on businesses that have not complied, leading potentially to court cases, fines and inevitably poor publicity for those that fail to meet the new regulations.
Food processors should not see the new regulations as another painful enforcement of bureaucracy from Brussels, but an opportunity to review current temperature control processes. Through our Process Services team, we are helping food-related businesses to fully assess all of the options available, even undertaking efficiency studies using temporary cooling equipment to help customers understand the best refrigerant solution for their plant.
Those that have not yet acted on R22 need to do so urgently. But rushing ahead with a poorly planned strategy that does not include contingencies to deal with likely real-life issues could create further problems. Informed, experienced and unbiased advice is needed to steer companies through this change.
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