Food Manufacturing | CO2 Transcritical Refrigeration
Comprehensive Services for a Groundbreaking Design-Build Project
CoolSys made a noteworthy contribution to the rapidly growing field of sustainable buildings and natural refrigeration with a unique design-build refrigeration and controls project that utilizes one of the largest transcritical CO2 installations in U.S. history.
The experts at CoolSys provided full building MEP and Refrigeration engineering design, handled energy management system design and installation, procured equipment, installed refrigeration systems, and managed the refrigeration and control/EMS process for a new, 325,000 square foot, first-of-its-kind facility for processing, cooking, freezing, and shipping high-quality meal kits.
Located in Goodyear, Arizona, the facility is not only notable for its massive CO2 refrigeration system but also for housing one of the largest industrial kitchens in North America.
The project was a highly complex undertaking, with about half of the square footage dedicated to refrigerated storage and the other half to a sophisticated food-preparation area.
To provide full building MEP and refrigeration engineering design, handle energy management system design and installation, procure equipment, install refrigeration systems and manage the refrigeration and control/EMS process for a new, 325,000 square foot, first-of-its-kind facility for processing, cooking, freezing and shipping high-quality meal kits.
One of the greatest challenges CoolSys faced in both the design and implementation for the facility was its location. Until recently, it was considered folly to attempt a transcritical CO2 refrigeration system capable of reaching -10 ̊ F—and particularly one the size of this project—in the unhospitable climate of the Arizona desert, where summertime temperatures can reach 120 ̊ or more. It was widely believed to be impossible to create an energy-efficient transcritical CO2 system in such a hot climate. Those assumptions, however, have been proven wrong.
In contrast to the extreme summer heat, winter temperatures in the Arizona desert can drop to near freezing, requiring equipment that can handle outside temperature variations of 80 ̊ or more.
Due to ongoing worldwide economic and supply-chain challenges—as well as the size and scope of the project—the customer was, understandably, conscious of staying on budget while maintaining its high standards for quality and safety.
One of the greatest challenges CoolSys faced in both the
design and implementation for the facility was its location. Until recently, it
was considered folly to attempt a transcritical CO2 refrigeration system
capable of reaching -10 ̊ F—and particularly one the size of this project—in
the unhospitable climate of the Arizona desert, where summertime temperatures
can reach 120 ̊ or more. It was widely believed to be impossible to create an
energy-efficient transcritical CO2 system in such a hot climate. Those
assumptions, however, have been proven wrong.
In contrast to the extreme summer heat, winter temperatures in the Arizona
desert can drop to near freezing, requiring equipment that can handle outside
temperature variations of 80 ̊ or more.
CoolSys worked closely with the client’s project managers to understand and meet its needs for equipment, budget and so forth. As with all of its customers, CoolSys sourced equipment from a wide variety of highly regarded manufacturers to get the best-performing components for each job at a price that fit within the client’s budget.
Total Square Footage
Refrigerated Square Footage
Packaged HVAC Units
Evaporator Coils
To keep 18 rooms comprising approximately 160,000 square feet of refrigerated space in the massive facility at the required temperatures, CoolSys procured and installed four transcritical CO2 rack systems, totaling over 16,000 MBH of compressor capacity, in the building’s machine room.
Each of the four racks utilizes a rooftop adiabatic gas cooler to reject heat. In total, the system supplies refrigeration for 78 evaporator coils in the refrigerated sections of the building. CoolSys recommended adiabatic coolers for efficient performance in the desert, using significantly less water than conventional evaporative condensers.
CoolSys installed two adiabatic fluid coolers on the roof that provided condenser water to condensing units for eight blast chillers in the food preparation area of the facility. Inside the building, CoolSys installed 78 evaporator coils that supply refrigeration for about half of the 352,000-square-foot facility.
CoolSys installed dedicated, packaged CO2 condensing units and associated piping for two food processing spiral chillers, as well as stainless steel piping, a building control system—including complete refrigeration system energy management—and leak detection in each refrigerated space.
The result was a project that came in on spec and on time. In addition, value engineering during the project’s design phase resulted in $1 million in savings compared with the original design.
Capital Cost Avoidance Secured
Transcritical CO2 Systems
3,000A, 480/227V Electrical Services
MBH Compressor Capacity
CoolSys is known nationwide for its broad range of design-build services for a wide variety of client needs, from the massive, single-site build-out in Arizona to coordinated, simultaneous work in hundreds of sites across the county and everything in between. We offer end-to-end design-build for refrigeration projects, professional project management (with or without equipment purchasing) and national refrigeration programs—including refrigeration conversions.
Unlike most of its competitors, CoolSys has its own engineering and energy optimization division. The team offers standalone services and collaborates with other CoolSys divisions on engineering and design-build projects. In addition, CoolSys is recognized nationwide as a leader in transcritical CO2 technology, with more than 500 technicians trained in CO2 and more than 250 CO2 projects completed across the U.S.
Contact CoolSys to see how our integrated design-build approach can move your project forward.
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