Related Commercial Resources

CHAPTER 47

FOOD SERVICE AND GENERAL COMMERCIAL

REFRIGERATION EQUIPMENT
Refrigerated Cabinets ................................................................................................................... 47.1
Food Freezers ............................................................................................................................... 47.3
Blast Chillers and Blast Freezers ................................................................................................. 47.3
Walk-In Coolers/Freezers ............................................................................................................. 47.3
Vending Machines ......................................................................................................................... 47.5
Ice Machines ................................................................................................................................. 47.7
Preparation Tables ........................................................................................................................ 47.7

F OOD service requires refrigerators that meet a variety of needs.

This chapter covers refrigerators available for restaurants, fast-
food restaurants, cafeterias, commissaries, hospitals, schools, con-
shapes, sizes, and capacities are available on a custom basis from
some manufacturers. Chapter 46 discusses display cabinets in great
detail.
venience stores, grocery stores, and other specialized applications. There are many varied adaptations of refrigerated spaces for stor-
Many refrigeration products used in food service applications are ing perishable food items. Reach-ins, by definition, are medium- or
self-contained, and the corresponding refrigeration systems are con- low-temperature refrigerators small enough to be moved into a
ventional. Some systems, however, do use ice for fish, salad pans, or building. This definition also includes refrigerators and freezers
specialized preservation and/or display. Chapters 46 and 48 have built for special purposes, such as mobile cabinets or refrigerators
further information on some of these products. on wheels and display refrigerators for such products as beverages,
Generally, electrical and sanitary requirements of refrigerators pies, cakes, and bakery goods. The latter cabinets usually have glass
are covered by criteria, standards, and inspections of Underwriters doors and additional lighting to illuminate the product. Candy
Laboratories (UL), NSF International, and the U.S. Public Health refrigerators are also specialized in size, shape, and temperature.
Service. Refrigerated vending machines satisfy the general definition of
reach-ins; however, because they also receive coins and dispense
REFRIGERATED CABINETS products individually, they are classified separately. Generally, the
full product load of a vending machine is not accessible to the cus-
Reach-In Cabinets tomer as in normal reach-in cabinets. Beverage-dispensing units dis-
The reach-in refrigerator or freezer is an upright, box-shaped pense a measured portion into a cup rather than in a bottle or can.
cabinet with straight vertical front(s) and hinged or sliding doors Reach-in refrigerators have doors on the front. Refrigerators that
(Figure 1). It is usually about 750 to 900 mm deep and 1800 mm have doors on both front and rear are called pass-through or reach-
high and ranges in width from about 900 to 3000 mm. Capacities through refrigerators (Figure 2). Doors are either full height (one
range from about 500 to 2500 L. Undercounter models 900 mm high per section) or half height (two per section). Doors may have win-
with the same dimensions are also available. These capacities and dows or be solid, hinged, or sliding.
dimensions are standard from most manufacturers.
The typical reach-in cabinet (Figure 1) is available in many styles Roll-In Cabinets
and combinations, depending on its intended application. Other Roll-in cabinets are very similar in style and appearance to
reach-in cabinets, but vary slightly in construction and functional-
Fig. 1 Reach-In Food Storage Cabinet Features ity. Roll-ins (Figure 3) are usually part of a food-handling or other

Fig. 2 Pass-Through (Reach-Through) Refrigerator

Fig. 1 Reach-In Food Storage Cabinet Features

The preparation of this chapter is assigned to TC 10.7, Commercial Food

and Beverage Cooling, Display and Storage. Fig. 2 Pass-Through (Reach-Through) Refrigerator

47.1
Copyright © 2006, ASHRAE
47.2 2006 ASHRAE Handbook—Refrigeration (SI)

Fig. 3 Open and Enclosed Roll-In Racks a minimum of 1°C core product temperature, with the most desir-
able average temperature close to 3°C. Low-temperature refrig-
erators cover a range of core product temperatures between –23 and
–12°C. The desirable average core product temperature is –18°C for
frozen foods and –20.5°C for ice cream. Both temperature ranges
are available in cabinets of many sizes, and some cabinets combine
both ranges.
Typical Construction
Refrigerators are available in two basic types of construction.
The older style is a wood frame substructure clad with a metal inte-
rior and exterior. The newer style is a welded assembly of exterior
panels with insulation and liner inserts.
Exterior. Materials used on exteriors (and interiors) are stainless
steel, painted steel, aluminum-coated steel, aluminum, and vinyl-
clad steel with wood grain or other patterns. The requirements are
for a material that (1) matches or blends with that used on nearby
equipment; (2) is easy to keep clean; (3) is not discolored or etched
Fig. 3 Open and Enclosed Roll-In Racks by commonly used cleaning materials; (4) is strong enough to resist
denting, scratching, and abrasion; and (5) provides the necessary
Fig. 4 Roll-In Cabinet, Usually Part of a Food-Handling or frame strength. The material chosen by an individual purchaser
Other Special-Purpose System depends a great deal on layout and budget.
Interior. Shelves, usually three or four per full-height section,
are standard interior accessories. Generally, various types of shelf
standards are used to provide vertical shelf adjustment.
Racks for roll-in cabinets are generally fitted with slides to handle
460 by 660 mm pans, although some newer systems call for either 300
by 510 mm or 300 by 460 mm steam table pans. Racks designed for
special applications are available but usually custom designed.
Manufacturers and contractors offer various methods of floor
insulation. This is important if the roll-in holds frozen food.
Specialty Applications
Reach-in and roll-in cabinets are regularly modified and adapted
to fit the needs of many specialty applications. Variations from stan-
dard construction practices are needed to meet the different temper-
ature, humidity, product volume, cleanliness, and other specifications
of various refrigeration applications.
Food Service. These applications often require extra shelves or
tray slides, pan slides, or other interior accessories to increase food-
holding capacity or make operation more efficient. Because certain
stored foods create a corrosive atmosphere in the enclosure, the
evaporator coil may have special coatings or fin materials to pre-
Fig. 4 Roll-In Cabinet, Usually Part of Food-Handling or vent oxidation. As use of foods prepared off-premises increases,
Other Special-Purpose System on-site storage cabinets are becoming more specialized; there is
growing pressure for designs that consider new food shapes, as
special-purpose system (Figure 4). Pans, trays, or other specially well as in-and-out handling and storage.
sized/shaped receptacles are used to serve a specific system need, Beverage Service. If reach-ins are required, standard cabinets, are
such as the following: used, except when glass doors and special interior racks are needed
for chilled product display. These cabinets generally have oversized
• Food handling for schools, hospitals, cafeterias, and other institu- refrigeration systems to allow for product pulldown cooling.
tional facilities
Meal Factories. These applications, which include airline or
• Meal manufacturing central feeding commissaries, require rugged, heavy-duty equip-
• Bakery processing ment, often fitted for bulk in-and-out handling.
• Pharmaceutical products Retail Bakeries. Special requirements of bakeries are the dough
• Body parts preservation (e.g., blood) retarder refrigerator and the bakery freezer, which permit the baker
The roll-in differs from the reach-in in the following ways: to spread the work load over the entire week and to offer a greater
variety of products. The recommended temperature for a dough
• The inside floor is at about the same level as the surrounding room retarder is 2 to 4.5°C. The relative humidity should be in excess of
floor, so wheeled racks of product can be rolled directly from the 80% to prevent crusting or other undesirable effects. In the freezer,
surrounding room into the cabinet interior. the temperature should be held at −18°C. All cabinets or wheeled
• Cabinet doors are full height, with drag gaskets at the bottom. racks should be equipped with racks to hold 460 by 660 mm bun
• Cabinet interiors have no shelves or other similar accessories. pans, which are standard throughout the baking industry.
Retail Stores. Stores use reach-ins for many different nonfood
Product Temperatures items. Drugstores often have refrigerators with special drawers for
Refrigerators are available for medium- or low-temperature storing biological compounds. (See the section on Nonfood Instal-
ranges. The medium-temperature range has a maximum of 5°C and lations.)
Food Service and General Commercial Refrigeration Equipment 47.3

Retail Florists. Florists use reach-in refrigerators for displaying Refrigeration Systems
and storing flowers. Although a few floral refrigerator designs are
Reach-in cabinets can be supported by either remote or self-con-
considered conventional in the trade, the majority are custom built.
tained refrigeration systems. The following two types of systems
The display refrigerator in the sales area at the front of the shop may
apply to all types of refrigeration equipment.
include a picture window display front and have one or more display
access doors, either swinging or sliding. A variety of open refriger- Self-contained systems, in which the condensing unit and con-
ators may also be used. trols are built into the refrigerator structure, are usually air-cooled
and are of two general types. The first type has the condensing unit
For the general assortment of flowers in a refrigerator, most re-
beneath the cabinet; in some designs it takes up the entire lower part
tail florists have found best results at temperatures from 4.5 to 7°C.
of the refrigerator, whereas in others it occupies only a corner at one
The refrigeration coil and condensing unit should be selected to
lower end. The second type has the condensing unit on top.
maintain high relative humidity. Some florists favor a gravity cool-
ing coil because the circulating air velocity is low. Others, how- Remote refrigeration systems are often used if cabinets are in-
ever, choose forced-air cooling coils, which develop a positive but stalled in a hot or otherwise unfavorable location where noise or
gentle airflow through the refrigerator. The forced-air coil has an heat of the condensing units would be objectionable. Other special
advantage when in-and-out service is especially heavy because it circumstances may also make remote refrigeration desirable.
provides quick temperature recovery during these peak condi- There are tradeoffs associated with locating a self-contained con-
tions. densing unit beneath the refrigerator; although the air near the floor is
Nonfood Installations. Various applications use a wide range of generally cooler, and thus beneficial to the condensing unit, it is usu-
reach-ins, some standard except for accessory or temperature modi- ally dirtier. Putting the condensing unit on top of the cabinet allows full
fications and some completely special. Examples include (1) bio- use of cabinet space, and, although air passing over the condenser may
logical and pharmaceutical cabinets; (2) blood bank refrigerators; be warmer, it is cleaner and less obstructed. Having the condensing
(3) low- and ultralow-temperature cabinets for bone, tissue, and red- unit and evaporator coil in the same location provides a refrigeration
cell storage; and (4) specially shaped refrigerators to hold column unit that can be removed, serviced, and replaced in the field as a whole.
chromatography and other test apparatus. Servicing can then be done at an off-site repair facility.
Blood bank refrigerators for whole blood storage are usually
standard models, ranging in size from under 566 to 1274 L, with the FOOD FREEZERS
following modifications: Some hospitals, schools, commissaries, and other mass-feeding
• Temperature is controlled at 3 to 5°C. operations use on-premises freezing to level work loads and operate
• Special shelves and/or racks are sometimes used. kitchens efficiently on normal schedules. Industrial freezing equip-
• A temperature recorder with a 24 h or 7 day chart is furnished. ment is usually too large for these applications, so operators use
either regular frozen food storage cabinets for limited amounts of
• An audible and/or visual alarm system is supplied to warn of
freezing or special reach-ins that are designed and refrigerated to
unsafe blood temperature variation.
operate as batch-type blast freezers.
• An additional alarm system may be provided to warn of power
failure. Chapter 16 covers industrial freezing of food products.

Biological, laboratory, and mortuary refrigerators involve the BLAST CHILLERS AND BLAST FREEZERS
same technology as refrigerators for food preservation. Most bio-
These types of units are designed to rapidly chill or freeze food
logical serums and vaccines require refrigeration for proper pres-
immediately after it has been cooked. Blast chillers and freezers are
ervation and to retain highest potency. In hospitals and laboratories,
used by food-service establishments, such as restaurants, hotels, and
refrigerator temperatures should be 1 to 3.5°C. The refrigerator
cafeterias, that cook large quantities of food items, chill or freeze
should provide low humidity and should not freeze. Storage in
them, and later reheat portions to be served. Blast chillers are
mortuary refrigerators is usually short-term, normally 12 to 24 h at
designed to allow operators to comply with food preparation, han-
1 to 3.5°C. Refrigeration is provided by a standard air- or water-
dling, and storage guidelines on preventing the growth of dangerous
cooled condensing unit with a forced-air cooling coil.
bacteria. These guidelines mandate that food be cooked to a mini-
Items in biological and laboratory refrigerators are kept in spe-
mum core temperature of 71°C and held there for at least 2 minutes.
cially designed stainless steel drawers sized for convenient storage,
The food is then immediately cooled to between 1 and 3°C within 2
labeled for quick and safe identification, and perforated for proper
to 4 hours. This not only prevents bacterial growth, but also helps
air circulation.
preserve the appearance, flavor, texture, and nutritional value of the
Mortuary refrigerators are built in various sizes and arrange-
food. Once cooled, refrigerated food must be stored at a temperature
ments, the most common being two- and four-cadaver self-contained
range of 1 to 3°C for a period not to exceed 5 days. Frozen food must
models. The two-cadaver cabinet has two individual storage com-
be maintained below –18°C and can be kept for 8 weeks or longer.
partments, one above the other. The condensing unit compartment is
above and indented into the upper front of the cabinet; also, ventila- Blast chillers for refrigerated food, and blast freezers for frozen
tion grills are on the front and top of this section. The four-cadaver food, are available in reach-in and roll-in models in a variety of sizes
cabinet is equivalent to two two-cadaver cabinets set together; the and capacities. They are designed to operate both as blast chillers
storage compartments are two cabinets wide by two cabinets high, and as storage refrigerators or freezers. Most units automatically
with the compressor compartment above. Six- and eight-cadaver change over to storage mode when the blast-chill cycle is com-
cabinets are built along the same lines. The two-cadaver refrigerator pleted. Many models are equipped with sophisticated microproces-
is approximately 965 mm wide by 2390 mm deep by 1955 mm high sor control systems that allow the operator not only to program the
and is shipped completely assembled. chill cycle, but also to obtain readouts, printouts, and alarms that
document and monitor the entire process. Built-in food probes are
Each compartment contains a mortuary rack consisting of a car-
commonly used to take readings and allow the control system to
riage supporting a stainless steel tray. The carriage is telescoping,
make adjustments if necessary.
equipped with roller bearings so that it slides out through the door
opening, and is self-supporting even when extended. The tray is
WALK-IN COOLERS/FREEZERS
removable. Some specifications call for a thermometer to be
mounted on the exterior front of the cabinet to show the inside Walk-in coolers/freezers are used in a wide variety of applica-
temperature. tions, but food sales and service facilities dominate all other uses.
47.4 2006 ASHRAE Handbook—Refrigeration (SI)

This type of commercial refrigerator is a factory-made, prefabri- ramp entry. Walk-in coolers (medium-temperature) called floorless
cated, modular version of the built-in, large-capacity cooling room. by the supplier are furnished with floor splines to fasten to the exist-
A walk-in cooler’s function is to store foods and other perishable ing floor to form a base for the wall sections. Generally, floor refrig-
products in larger quantities and for longer periods than reach-in eration losses are considered small in a floorless configuration.
refrigerators/freezers. Good refrigeration practice requires storing Level entry is becoming more important as the use of hand and
dissimilar unpackaged foods in separate rooms because they require electric trucks increases. The advantage and convenience of level
different temperatures and humidity and to prevent odors from some entry afforded by a floorless cooler can also be obtained by recessing
foods from being absorbed by others. The food cooler/freezer is a sectional insulated floor. Walk-in coolers (medium-temperature)
likely to be equipped with sturdy, adjustable shelving about 460 mm are the only applications that can be floorless or mounted on slab
deep and arranged in tiers, three or four high, around the inside concrete. Walk-in freezers must feature an insulated floor.
walls; another common option is rolling racks (basically shelving
on wheels), which are rolled directly into and out of the cooler. Refrigeration Systems
Large food operations may have three rooms: one for fruits and veg- Walk-ins can be served by remote or self-contained refrigeration
etables, one for meats and poultry, and one for dairy products. A equipment (see the section on Refrigerated Cabinets for more
fourth room, at –18°C, may be added for frozen foods. Smaller food details). There are various methods of application for self-contained
operations that use appropriate food packaging may require only refrigeration units (Figure 5). These self-contained units use com-
two rooms: one for medium-temperature refrigeration and one for plete refrigeration systems, usually air-cooled, in a single compact
frozen storage. package. The units are installed in the sectional cooler/freezer wall
or ceiling panels.
Operating Temperatures
There are two major temperature classes of walk-ins: low (–29 to Compressors
–23°C) and medium (–23 to –1°C). Coolers may be used to hold Walk-in coolers/freezers typically use either hermetic or semi-
sides or quarters of beef, lamb carcasses, crates of vegetables, and hermetic compressors. Hermetic compressors are typically rated
other bulky items. Food operations now rarely use such items. If between 0.4 and 3.7 kW. The compressor and motor are sealed in a
they do, the items are broken down, trimmed, or otherwise pro- gastight shell; when repairs are needed, the shell must be cut open
cessed before entering refrigerated storage. The modern cooler is and then resealed by welding it closed. Typical applications for the
not a storage room for large items, but a temporary place for quan- hermetic compressor are smaller food service, ice machines, and
tities of small, partially or totally processed products. beverage dispensers. Semihermetic compressors can have ratings
between 0.2 and 11 kW. They need less maintenance and have
Typical Construction longer life cycles (up to three times the life of hermetics), and pro-
Walk-in coolers/freezers are composed of prefabricated pan- vide a greater cooling capacity. Furthermore, the unit not being
els, which come in a variety of sizes that are shipped to the oper- housed in a shell allows for easy serviceability. Semihermetic com-
ator and assembled on site. The edges of the panels are usually of pressors are typically used in larger cooling applications. See Chap-
tongue-and-groove construction and either fitted with a gasket ter 34 of the 2004 ASHRAE Handbook—HVAC Systems and
material or provided with suitable caulking material to ensure a Equipment for more compressor information.
tight vapor seal when assembled. In most cases, the panels, refrig-
eration components, and controls are ordered separately and Evaporators
assembled on site, although some smaller units are supplied fully Evaporator coils are constructed of rust-free aluminum housing
assembled. Sizes are typically 7.5 to 70 m2 and 2.4 to 3 m high, or containing staggered copper tubes expanded into corrugated
about 18 to 210 m3; the average size appears to be in the range of aluminum fins. The evaporator fan motors are either 115 or 230 V.
55 m3. The modular walk-in cooler/freezer offers flexibility over Walk-in coolers (medium-temperature) typically feature an off-cycle
the built-in type. It can be easily erected and moved, and readily Fig. 5 Refrigeration Equipment Added to Make a Walk-In
altered to meet changing requirements, uses, or layouts by adding Cooler Self-Contained
standard sections. Modular walk-in coolers/freezers can be
erected outside a building, providing more refrigerated storage
with no building costs except for footings and an inexpensive roof
supported by the cooler. Exterior and interior surfaces may be
painted and can be made of galvanized steel, aluminum, alumi-
num-coated steel, stainless steel, or vinyl-clad steel.
The frames are filled with insulation and are covered with metal
on both sides. Polyurethane and polystyrene are two common types
of insulation. These foam plastic materials are both light and water-
resistant, and have improved thermal insulation in both self-
contained and remotely refrigerated sectional coolers.
Door Construction
A variety of optional accessories simplify opening and closing
doors. Triple-pane windows (heated on freezers), digital thermom-
eters, and light switches allow an operator to locate or inspect the
contents of the cooler/freezer without entering. An interior/exterior
kick plate provides protection when using ones foot to kick open or
close the door. Cam-lift hinges allow the door to swing open easily,
and should be coupled with an automatic door closer.
Walk-In Floors
Modular (insulated) floors can be purchased and integrated into Fig. 5 Refrigeration Equipment Added to Make a Walk-In
walk-in coolers/freezers, but the raised entry level requires a step or Cooler Self-Contained
Food Service and General Commercial Refrigeration Equipment 47.5

defrost, whereas freezers (low-temperature) use electric defrost or Fig. 6 Estimated 1994 Breakdown of Beverage Vending
hot-gas methods. Machines by Type

Refrigeration Sizing
When sizing the refrigeration system for a walk-in cooler or
freezer, consider the following factors:
• Heat transmission (heat gained through the walls, floors, and ceiling)
• Air infiltration
• Product load (heat removed from a product to cool it, and heat of
respiration from some fruits and vegetables)
• Supplemental loads (heat dissipated by people or mechanical
equipment inside the cooler/freezer)
• Post-defrost pulldown load
Maintenance and Operation
• Clean the condenser coil quarterly. This will increase the refrigera-
tor’s efficiency and extend the life of the equipment by reducing Fig. 6 Estimated 1994 Breakdown of Beverage Vending
compressor run time. Also, make sure air moves freely around the Machines by Type
compressor and condenser to help the system disperse heat. (Source: A.D. Little 1996)
• To prevent warm, moist air infiltration into the cooler, ensure that
the gaskets are in good condition, the door’s hinges are lubricated, inside a completely opaque insulated compartment. Some models
the auto-door closers are working, and, for walk-in coolers, that have a display window where sample products are placed in view,
strip curtains have been installed. but the products to be vended are contained behind an insulated door
• Keep the refrigerator’s evaporator coils clean, and check them on and cannot be seen by the consumer. These machines typically have
a regular schedule. Also, check for plastic bags, which can get a full-sized illuminated advertisement panel on the front. Glass-
caught against the evaporator, on the back side of walk-in cooler front units have a translucent panel that enables the purchaser to see
units. the product as it is vended. In this type of machine, the product itself
is illuminated and used to attract the purchaser’s attention. There are
• Maintain proper loading of products inside the cooler to avoid
various vending configurations but all machines fit into one of these
blocking air circulation.
categories.
• Keep the refrigerator’s evaporator drain line clean and open.
Often, pooled water on the bottom a cooler results from a plugged Refrigeration Systems
drain line. This makes the unit work harder and longer, thus con-
suming more energy. Vending machines use simple, self-contained refrigeration sys-
• In walk-in freezers, place heat tape in the evaporator’s drain line tems consisting of a compressor, evaporator coil, condenser, and
to ensure proper drainage during defrost. In addition, make sure capillary tube. The compressor and condenser are typically located
insulation is installed over the evaporator’s drain line with heat at the bottom of the unit, between the ground and the refrigerated
tape, to reduce the amount of heat load inside the freezer. cabinet. Refrigerant is piped through the capillary tube to an evap-
• Make sure defrost time clocks are set properly and do not defrost orator inside the refrigerated cabinet.
more than necessary. Avoid defrosting during peak demand rate The compressor consumes by far the most energy in the vend-
times, (typically between noon to 6:00 PM), when scheduled ing machine. Laboratory test results (Faramarzi 2005) indicate the
deliveries arrive, or when employees place a heavy use load on the compressor accounts for 65 to 75% of the total energy consumed
freezer. When a freezer goes into its defrost cycle, heat is added to (Figure 7). Oversized single-speed compressors are commonly
the evaporator (to defrost) and the compressor will not cycle on used to provide excess cooling capacity to pull down product tem-
regardless of the cooler’s temperature. Thus, avoiding adding heat peratures quickly after the machine is restocked. A condenser fan
to the freezer during the defrost times reduces a freezer’s energy operates concurrently with compressor cycling and uses less than
consumption. 10% of the total energy. The evaporator fan runs continuously to
• Turn off lights inside glass-door coolers at night, when customers distribute air through the refrigerated cabinet and consumes about
are not present, and leave them off all of the time in noncustomer 8% of total machine energy. Lighting systems usually remain on
areas. This saves energy and add less heat load to the cooler. the entire time a vending machine is plugged in. Different lighting
• Ensure high integrity of vapor barriers and insulated panels. systems are used, depending on the machine, but usually consume
Check regularly for punctured or broken panels and breaches 5 to 20% of the total energy. Dispensing mechanisms operate
around pipe penetrations through the panels. intermittently, whenever a product is purchased, and therefore do
not use a significant amount of energy (1 to 3%) compared to other
components.
VENDING MACHINES
Refrigerated vending machines are designed to store food and Cooling Load Components
beverages at a prescribed temperature and dispense product in Heat enters the refrigerated section of the cabinet by the follow-
exchange for currency. The U.S. refrigerated vending machine pop- ing methods:
ulation is approximately 4 100 000, of which about 87% dispense
canned and bottled beverages (Figure 6). The average energy usage • Released by the evaporator fan motor
for a typical vending machine is 10 800 MJ/year and is affected by • Released by the lighting (glass-front units only)
many factors (A.D. Little 1996). Generally, site owners are respon- • Conduction through the insulated envelope
sible for energy costs. • Infiltration through imperfections in construction such as cracks
in the box or improperly sealed delivery doors
Types of Refrigerated Vending Machines • Radiation through the glass front (glass-front units only)
Vending machines can be divided into two main categories: • Product restocking (warm product placed into the machine must
closed-front and glass-front. Closed-front units house products be cooled to acceptable temperature)
47.6 2006 ASHRAE Handbook—Refrigeration (SI)

Fig. 7 Energy Use by Component Typical Vending Machines ICE MACHINES

Ice machines are used in many commercial applications, includ-
ing bars, restaurants, gas stations, minimarts, delis, hotels, motels,
hospitals, and other institutional facilities. Ice machines can harvest
large quantities of ice and store it in holding bins, similar to those
found in hotel hallways next to vending machines or in restaurant
kitchens, where it is available for later use. Restaurants and mini-
marts, as well as other operations, require self-service ice production,
typically integrated into fountain beverage dispensers.
There are three main categories of ice machines: (1) cubers,
(2) flakers, and (3) nugget (chewable ice) makers. Ice machines
come in various sizes, with harvest rates between 110 and 635 kg
per 24 h. The Air-Conditioning and Refrigeration Institute (ARI)
maintains a database on certified commercial ice machines and stor-
age bins (ARI 2005), which tabulates ice harvest capacity, potable
water use, and energy consumption rate for all models. In addition,
condenser water use is tabulated for water-cooled models.
Typical Operation and Construction
Ice is created and then harvested, dropping into the storage bin
until the bin fills up, at which point ice production stops. When the
level of ice in the storage bin falls below a threshold amount, the
head unit cycles back on and refills the bin.
Similar to all mechanical refrigeration, ice machines are com-
prised of a compressor, evaporator, expansion valve, and condenser.
Cubed ice forms on the evaporator plate. When the ice is fully
formed, the refrigeration system cycles in reverse, heating the evap-
Fig. 7 Energy Use by Component For Typical orator plate and melting a small layer of ice to release the sheet into
Vending Machines the storage bin. Various methods are used to release the sheet of ice
Data are for 24 h test with ambient conditions 35°C and 65% rh. from the evaporator plate. Flake and nugget machines form ice on the
(Source: Faramarzi 2005) inside of a cylinder, which features a screw (auger) that shaves off the
ice. Shaved ice is forced out the top, where it falls into a storage bin.
The nugget machine adds a cone for the ice to pass through, allowing
Sensitivity to Surroundings the shavings to clump together and form nuggets. Flake and nugget
A vending machine’s refrigeration system is highly vulnerable to machines use all the water that enters the ice machine to produce ice.
changes in its surroundings. Cooling load can be increased by high Cube machines use a small amount of water to purge scale and min-
ambient temperatures, which raise head pressure, resulting in loss of eral deposits, to prevent damage to the evaporator plate. Head units
refrigeration effect and increased compression ratio. It also in- and storage bins can be mixed and matched to meet specific produc-
creases conduction, radiation, and sensible infiltration loads. High tion and demand characteristics of the installation.
humidity increases latent infiltration load, and can cause extreme Storage bins come in multiple sizes, and are insulated with
ice build-up on the evaporator coil. This may severely restrict air- foamed-in-place polyurethane, with doors that are hinged to stay
flow through the unit and minimize the amount of heat absorbed by open during ice removal. No mechanical refrigeration is used to
the refrigerant. Exposure to sunlight greatly increases heat gain into maintain the frozen ice in the storage bin (i.e., ice machines only use
the refrigerated space through direct solar radiation, especially in energy while making ice).
glass-front machines, raises the sol-air temperature of the cabinet
exterior, and increases conduction load. Exposure to high-intensity Refrigeration Systems
lighting fixtures can have a similar (but smaller) effect. Each category of ice machine can have a remote or self-
Condenser coils are usually located in the bottom of the machine, contained air- or water-cooled condenser. See the section on Re-
with air intakes at ground level. The coils often get dirty and clogged. frigerated Cabinets for a more detailed description of refrigeration
Dirty condenser coils lose their heat rejection effectiveness, which systems.
reduces refrigeration capacity and increases compressor power use. Maintenance and Operations
Steel security cages are often placed around machines, especially The site owner should ensure proper ice machine performance by
when they are outdoors. These cages trap heat rejected by the con- adhering to the manufacturer’s recommended maintenance sched-
denser as it exits the rear of the machine. Trapped heat increases the ule and monitoring the following parameters (Moore 2000):
inlet air temperature at the condenser, causing operations at higher
condensing temperatures. • Perform regular cleaning and sanitization to discourage bacterial
growth.
Maintenance and Operation • Check water system and evaporator for scale build-up.
• Check for talc or mineral build-up in reservoir.
The site owner can improve vending machine efficiency by tak- • Check pump motor operation (e.g., broken impeller, slow pump-
ing these measures: ing).
• Check water flow through external water filter.
• Keep machines in cool/shaded locations to minimize sun exposure
• Check strainer, inlet water valve screen, or float valve for obstruc-
• Keep condenser coils clean. tion.
• Install a controller that will shift the unit to low power based on • Inspect float valve assembly, adjustment, and operation.
low traffic or low sales rate. • Check air filter, condenser fan blade, and coil for dust and grime.
Food Service and General Commercial Refrigeration Equipment 47.7

• Check for proper drainage or water back-up in the bin that can tion, are medium-temperature refrigerators small enough to be
melt ice away. moved into a building.
• Inspect the water overflow of the reservoir that washes ice away.
Product Temperatures
• Check the bin control for proper location and operation.
Refrigerated prep tables are available for medium-temperature
ranges: a maximum of 5°C (for potentially hazardous foods) and a
PREPARATION TABLES minimum of 0.6°C core product temperature, with the most
desirable average temperature close to 3°C. The refrigerated rail is
The preparation (or “prep”) table is a box-shaped cabinet with an
required to maintain food product between 0.6 and 5°C. Maintain-
open top section and sliding drawers or hinged doors on the bottom
ing uniform bin product temperatures in prep tables is always a
storage compartment (Figure 8). It is usually about 0.75 to 0.9 m
challenge. Cooling is provided by circulation of cold air under bins.
deep and 0.9 m high, and ranges in width from about 0.9 to 3 m. The
Air does not reach each bin evenly, causing exposure of some bins
prep table is designed to hold and provide easy access to pans of
to larger air volumes and, consequently, varying air temperature.
food or condiments. Cabinet capacities range from about 0.3 to over
1 m3. A unit may or may not be equipped with a lower refrigerated Typical Construction
compartment. These capacities and dimensions are standard from
Refrigerated prep tables are available in two basic types of con-
most manufacturers.
struction. Cold wells may be designed to drop into existing counter-
Typical types of prep tables include refrigerated sandwich units, tops, and do not have a refrigerated cabinet. More common designs
pizza preparation tables, and buffet tables. Prep tables, by defini- use a welded assembly of exterior panels with insulation and liner
inserts.
Materials used on exteriors and interiors are stainless steel,
Fig. 8 Refrigerated Preparation Table painted steel, aluminum-coated steel, aluminum, and vinyl-clad
steel with wood grain or other patterns. Materials must (1) match or
blend with that used on nearby equipment; (2) be easy to keep clean;
(3) not be discolored or etched by common cleaning materials;
(4) be strong enough to resist denting, scratching, and abrasion; and
(5) provide the necessary frame strength. The material chosen by an
individual purchaser depends a great deal on layout and budget.
Shelves are standard interior accessories, and are usually adjust-
able and furnished three or four per full-height section.
ENERGY EFFICIENCY OPPORTUNITIES
Products discussed in this section use different components and
design strategies. The following is a list of options that are or can be
used in these products. Some of the options are mature and tested in
the industry, whereas others are emerging technologies. Designers
must balance energy savings against customer requirements, manu-
facturing cost, system performance, reliability, and maintenance
costs. Several of these options can be applied to all refrigeration sys-
tems; others apply only to specific types of equipment. The follow-
ing list defines some of the energy efficiency measures that may be
implemented. Table 1 shows applicability to the equipment dis-
Fig. 8 Refrigerated Preparation Table cussed in this chapter.

Table 1 Applicability of Energy-Efficiency Opportunities to Refrigeration Equipment

Roll-Ins/ Vending Preparation
Reach-Ins Walk-Ins Machines Ice Machines Tables
High-efficiency compressors with capacity modulation capability X X X X X
High-efficiency evaporator and condenser coils X X X X X
Condenser fan and evaporator fan ECM X X X X X
Auto door-closers X
Compact fluorescent lights X
Liquid-to-suction heat exchangers X X X X
Insulation for bare suction lines X X
Expansion valve with superheat control X X
Efficient defrost X X
Strip curtains or plastic doors X
Occupancy sensors X
Evaporator fan controller X
(Coolers only)
High-efficiency lighting system X
Improved airflow through refrigerated cabinet X X
Airtight cabinet construction X X
Improved insulation X X X
Lids X
47.8 2006 ASHRAE Handbook—Refrigeration (SI)

• High-efficiency compressors with capacity modulation capa- when compressor(s) cycle off and there is no refrigerant flow
bility enable the variable-speed-driven compressor to match through the evaporator. They should not be used if (1) the com-
capacity with the varying cooling load. pressor runs all the time with high duty cycle, (2) the evaporator
• High-efficiency evaporator and condenser coils with increased fan does not run at full speed all the time, (3) the evaporator fan
surface area and conductivity can transfer heat with the air more motor runs on polyphase power, (4) the evaporator fan motor is
effectively. not shaded pole, or (5) the evaporator does not use off-cycle or
• Condenser fan and evaporator fan electronically commutated time-off defrost.
motors (ECMs) use less power than shaded-pole motors. They • High-efficiency lighting systems include electronic ballast and
also can incorporate variable-speed controllers. efficient light bulbs.
• Auto door-closers ensure that the door is pulled securely shut • Improved airflow through refrigerated cabinets can reduce the
when it is within 25 mm of full closure, thereby reducing air infil- input energy required by the evaporator fan and promote uniform
tration. cooling of products inside the cabinet.
• Compact fluorescent lights (CFLs) can replace the incandes- • Airtight cabinet construction eliminates infiltration of warm
cent bulb, reducing energy consumption and heat production. and moist air.
CFLs can now operate in cooler/freezer temperature ranges. • Improved insulation reduces conductive heat transfer through
• Liquid-to-suction heat exchangers allow suction gas leaving the the walls of the refrigerated cabinet.
evaporator to absorb heat from liquid refrigerant entering the • Closing lids on refrigerated prep tables during non-use periods
evaporator, increasing the subcooling and cooling capacity of the substantially reduces energy use.
system.
• Insulation for bare suction lines reduce system losses. REFERENCES
• Expansion valve with superheat control reduces the mass flow ARI. 2005. Directory of certified automatic ice-cube machines and ice stor-
rate of refrigerant as a function of superheat, thereby reducing age bins 810/820. Air-Conditioning and Refrigeration Institute, Arling-
compressor power under low load. ton, VA. http://www.ari.org/cert/directories/acim/acim0001.pdf.
A.D. Little, Inc. 1996. Energy savings potential for commercial refrigera-
• Efficient defrost methods, such as hot gas or cool gas, remove ice tion equipment. Report prepared for Building Equipment Division,
from the coil in a comparatively short period of time while adding Office of Building Technologies, U.S. Department of Energy, Washing-
little heat to the refrigerated space. Defrost should be controlled ton, D.C.
with temperature termination so that compressor off-time lasts Davis Energy Group. 2002. Codes and standards enhancement initiative for
only as long as necessary to melt the ice. PY 2001: Title 20 standards development—Draft analysis of standards
• Strip curtains or plastic doors provide a barrier against ambient options for refrigerated beverage vending machines. Report prepared for
air infiltration when the walk-in cooler/freezer door is open. Pacific Gas and Electric Company, San Francisco.
Faramarzi, R. and S. Mitchell. 2005. Performance evaluation of typical
• Occupancy sensors can be installed to turn interior lights on and glass-front refrigerated beverage vending machines under various ambi-
off as a function of occupancy and traffic. This also reduces a ent conditions. Southern California Edison Refrigeration and Thermal
source of heat inside the cooler/freezer. Test Center, Irwindale.
• An evaporator fan controller for walk-in coolers reduces air- Moore, D. 2000. Low ice production: What to do if your unit just won’t keep
flow of evaporator fans in medium-temperature walk-in coolers up. http://www.hoshizakiamerica.com.

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