Energy efficient Control Systems

  • EEV floating control
  • Ambient tracking
  • ECA Approved

Energy Managment For The Food Industry

With the escalating cost of fuel coupled with the importance of reducing global carbon emissions the reduction of energy use is a prime concern for all businesses. Refrigeration and temperature control make up a significant percentage of any food industry businesses energy requirements. Effective control of these systems can have a positive impact both helping the environment and financially giving long term savings to your business.

For many companies, energy costs become just a fixed overhead. Tektroniks produces efficient refrigeration devices which are designed to save energy and offer a way for companies to significantly reduce these overheads.

Making energy efficiency a priority makes sound financial sense. You can take advantage of the government tax incentives such as the ECA scheme and add this to reduce running costs to give your initial investment a very short pay-back period, potentially less than a year.

At Tektroniks we have advanced the technology of refrigeration control to give true long terms savings and to reduce the levels of energy needed to operate and maintain effective refrigeration systems.

Tektroniks unique EEV (Electronic Expansion Valve) control strategy is designed to help create a stable return suction pressure within the refrigeration system within your display cases and cold stores, this stable return suction pressure has a significant effect on improving plant operation and reducing energy consumption. Below is a comparison of our EEV technologies versus the standard TEV (Thermostatic Expansion Valve) commonly used.

Standard TEV Control results in increased energy use
Fig 1 shows the results of analysis on the affect of the evaporator inlet and outlet temperatures, using a thermostatic expansion valve on standard temperature control. The erratic appearance of the inlet and outlet temperatures caused buy the inability of the valve for close control. Results in increased energy use across the whole system.

Graph of Thermostatic Expansion Valve

More efficient EEV Control
By comparison, using the same laboratory conditions and control criteria but changing the valve and method of control to Tektroniks EEV, the result is a much closer, smoother control (Fig 2). A more stable system will reduce energy use.

Graph of Electronic Expansion Valve

Configuration 1 - Standard TEV setup

System
Setup
E E V
state
T E V
State
Floating
Head
L/S HX
State
Cond Set
Point
 OFFONOFFOFF40°C

kW/hrs Start1343.00KW/Hrs
kW/Hrs Finish2064.50kW/hrs
Total Energy use - All Equipment721.50kW/hrs
Total Energy use - Display Cases300.09kW/hrs
Total Energy Use - Pack + Condr421.41KW/hrs

As the 2nd configuration table shows, using Tektroniks EEV technologies reduced energy consumption by the standard display case refrigeration system from 421.41 to 363.91 KW/Hrs, this represents a saving of 13.64%*

Configuration 2 - Tektroniks EEV control

System
Setup
E E V
state
T E V
State
Floating
Head
L/S HX
State
Cond Set
Point
 ONOFFOFFOFF40°C

kW/hrs Start2094.000KW/Hrs
kW/Hrs Finish2753.000kW/hrs
Total Energy use - All Equipment659.000kW/hrs
Total Energy use - Display Cases295.086kW/hrs
Total Energy Use - Pack + Condr363.914KW/hrs

However if you display cases and cold stores are connected to external refrigeration systems then even greater energy savings can be gained by also incorporating Tektroniks Ambient Temperature Technologies.


How Tektroniks Ambient Tracking Technologies Work

By tracking ambient temperature and working within the condenser design specification the Tektroniks Ambient Tracking system optimises the condenser control, this is extremely beneficial during winter months and at night when outside temperatures are naturally lower. By optimising the condenser controls our system greatly reduces the refrigeration plants condenser pressure.

Fig 3 below shows data retrieved from a live site showing the effect on both the condenser and suction pressures when the control was changed to Tektroniks ambient tracking from standard operation.

Graph of

Configuration 3 - Tektroniks EEV, TEV, Floating head and L/S HX setup

System
Setup
E E V
state
T E V
State
Floating
Head
L/S HX
State
Cond Set
Point
 OFFOFFONON25°C

kW/hrs Start2766.7KW/Hrs
kW/Hrs Finish3352.3kW/hrs
Total Energy use - All Equipment585.6kW/hrs
Total Energy use - Display Cases295.218kW/hrs
Total Energy Use - Pack + Condr290.382KW/hrs

Configuration 3 shows the data from the final test in the independent trial. The configuration introduced energy reduction including the Tektroniks EEV case control and Tektroniks Ambiant Tracker for the condenser. The resulting energy saving compared to the configuration 1 standard setup was 32.94%*.

* Independent tests carried out and Data supplied by retail engineering support limited. Results and savings will vary due to system design and climatic conditions and although results are accurate for these test purposes, they cannot be guaranteed in all cases.