10 August

Your Refrigeration is an Investment

Opening or taking over a supermarket comes with a long list of decisions, and refrigeration is one of the areas where poor planning can become expensive very quickly.

For a new supermarket owner, it can be tempting to focus first on choosing cabinets and equipment. In practice, the refrigeration system needs to be considered as part of the whole store, including the product mix, floorplan, refrigeration plant, electrical requirements, energy use, servicing and future growth.

Understanding the basics before you commit to equipment can help avoid costly changes later and make sure the refrigeration system is suitable for the way the store will actually operate.

Start With the Store Layout and Product Mix

Before selecting equipment, work out what products you will be selling, how much refrigerated display space you need and where those categories will sit within the store.

Fresh meat, dairy, deli, frozen food, produce, drinks, ready meals and grab-and-go products all have different storage and display requirements. Cool rooms and freezer rooms also need to be factored into the overall refrigeration load.

This planning stage is important because the size and type of refrigeration system should be based on the store’s actual requirements rather than simply fitting equipment into the available space.

Integral or Remote Refrigeration?

Supermarket refrigeration generally falls into two broad categories: integral and remote.

Integral cabinets have their own refrigeration system built into the unit and are commonly used where flexibility is important, particularly in smaller stores, promotional areas or for standalone displays.

Remote cabinets are connected to a central refrigeration plant located elsewhere in the building. This type of system is commonly used in larger supermarkets where multiple refrigerated cases, cool rooms and freezer rooms operate from a central plant.

The right option depends on the size of the store, available space, electrical capacity, operating costs and the long-term plans for the business. In many stores, a combination of remote and integral equipment may be the most practical solution.

Consider Refrigeration Plant Location Early

If the supermarket will use a central refrigeration plant, its location should be considered early in the design process rather than after the rest of the store has been planned.

Depending on the site, the plant may be located in a dedicated back-of-house plantroom or externally, including on a rooftop. Both options can work well, but the choice may affect ventilation, noise, pipe runs, construction requirements, service access and the amount of internal floor space available.

Leaving this decision too late can result in longer pipe runs, compromised access or additional building work that could have been avoided during the original design.

Look Beyond the Appearance of the Cabinets

Refrigerated display cases are an important part of the overall look of a supermarket, but appearance should only be one part of the decision.

Energy performance, shelf capacity, product visibility, lighting, door configuration, cleaning, service access, spare parts availability and refrigerant type are all worth considering before making a purchase.

It is also important to think about how the cabinet will perform over time. Commercial refrigeration operates continuously, so even relatively small differences in energy consumption can have a noticeable impact on operating costs over the life of the equipment.

Think About Whole-of-Life Cost

The cheapest equipment to purchase is not always the cheapest equipment to own.

When comparing options, it is worth considering the purchase price together with installation, electricity consumption, servicing, repairs, refrigerant costs and eventual replacement.

Energy-efficient cabinets, good system controls, correctly designed refrigeration plant, LED lighting, efficient fans and suitable door systems can all contribute to reducing ongoing operating costs.

For a supermarket owner, a slightly higher capital cost can sometimes make sense if the equipment offers better energy performance, reliability and serviceability over its working life.

Understand the Refrigerant Being Used

Refrigerant choice has become an increasingly important part of commercial refrigeration planning as the industry moves towards lower-impact options, including natural refrigerants such as CO₂ and R290.

For a new supermarket owner, the important issue is not simply choosing the newest refrigerant available. The system needs to be appropriate for the store, supported by suitably trained technicians and considered in the context of long-term servicing, efficiency and future refrigerant availability.

Before investing, make sure you understand what refrigerant the equipment uses, why it has been selected and whether the system is likely to remain practical to operate and maintain over the expected life of the equipment.

Plan for Maintenance From the Beginning

Refrigeration equipment operates around the clock, so ongoing maintenance should be part of the planning process from the outset.

Preventative maintenance can help identify worn components, temperature issues and developing faults before they become larger and more expensive problems. It can also help equipment operate efficiently and extend its service life.

Regular servicing may include checks of cabinet temperatures, fans, doors, seals, condensers, evaporators, electrical components, controllers, alarms, drainage and the refrigeration plant itself.

For supermarket owners, having access to reliable refrigeration service support is just as important as choosing the equipment in the first place.

Make Sure Equipment Can Be Serviced

Service access is often overlooked during store design, particularly when refrigeration equipment is being incorporated into cabinetry, walls, shelving or other shopfitting.

A cabinet may fit perfectly on a drawing but still be difficult to repair once the surrounding fitout is complete. Poor access can increase service time, complicate repairs and, in some cases, require surrounding fixtures to be removed before technicians can reach key components.

Plant, cabinets, electrical components, controllers and pipework should all be positioned with future servicing in mind.

Allow for the Store to Change

A supermarket is unlikely to remain exactly the same for the life of its refrigeration system.

Product categories change, stores are refurbished and additional refrigerated space may be required as the business grows or when food or shopping trends change. Where possible, it is worth considering flexibility for future expansion when planning refrigeration capacity, electrical infrastructure and available space.

Allowing for these changes during the initial design is generally much easier than modifying major refrigeration infrastructure later.

Involve Your Refrigeration Contractor Early

Refrigeration works best when it is considered as part of the overall store design rather than as a separate purchase towards the end of a project.

An experienced commercial refrigeration contractor can assist with equipment selection, plant sizing, cool rooms, controls, electrical requirements, installation, commissioning and ongoing servicing, while also working with builders, shopfitters and other contractors involved in the project.

Bringing refrigeration specialists into the process early can help identify potential issues before construction begins and ensure that the equipment, plant and store layout work together properly.

Avoid Making Decisions on Price Alone

There is always pressure to manage capital costs when opening or refurbishing a supermarket, but refrigeration is one area where choosing purely on the lowest upfront price can create higher costs later.

When comparing quotations, check that the scope is genuinely comparable and includes the equipment, installation, controls, commissioning, warranty and after-sales support required.

A good supermarket refrigeration system should provide reliable temperature control, strong product presentation, reasonable energy use and equipment that can be maintained and supported throughout its working life.

For supermarket owners who are new to the industry, taking the time to understand these fundamentals before purchasing equipment can help avoid costly mistakes and provide a much better foundation for the store.

Refrigeration Quote Checklist

When reviewing a refrigeration quote, check whether it includes:

The exact make and model of equipment being supplied, rather than a general description.
Refrigeration capacity appropriate for the store and the expected product load.
Refrigerant type and whether it is suitable for the long-term operation of the store.
Energy performance of the cabinets and refrigeration plant.
Refrigeration plant, including compressors, condensers and associated equipment where required.
Controls and monitoring systems, including alarms and temperature control.
Pipework, insulation and refrigerant charge, including correct welding practices and pressure testing.
Electrical work and switchboards, or a clear explanation of what electrical work is excluded.
Delivery and positioning of equipment.
Installation labour.
Commissioning and testing before the equipment is handed over.
Cool rooms and freezer rooms, where applicable.
Drainage and condensate requirements.
Builders’ works, penetrations, lifting or crane costs, if required.
Removal or disposal of existing equipment during a refurbishment.
Warranty period and exactly what the warranty covers.
Spare parts availability for the equipment being proposed.
Local service support if something goes wrong.
Preventative maintenance options once the store is operating.
After-hours and emergency breakdown support.
Any exclusions that may result in additional costs later.

It is also worth asking who will install and commission the refrigeration system. A company that can design, supply, install, commission and maintain the equipment provides a very different level of accountability compared with using multiple suppliers.

Baker Refrigeration can assist with the design, supply, installation, maintenance and servicing of commercial refrigeration systems for supermarkets across Australia.

One last note, don’t forget to check if you are able to receive a rebate!