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Problem

At retail creameries nationwide, frozen ice cream/ gelato display cases are equipped with compressors operating at -20°F to maintain ice cream at 0°F. Often in summer, due to increased cooling load, the compressor unit will seize and fail. This presents multiple issues to the franchisee:

  1. The display case is not able to maintain the ice cream at 0°F
  2. The risk of second compressor failure is much higher due to excessive operating loads on the remaining compressor
  3. The cost of purchasing and installing a new compressor overnight is very expensive
  4. Moving ice cream to a storage freezer and continuing retail from the storage freezer is cumbersome, inconvenient and results in unsatisfied customers

Solution

In August 2015, when the problem was first presented to RGEES, LLC by a Cold Stone Creamery franchise owner in Asheville, NC, engineers at RGEES, LLC proposed a COLD BATTERY utilizing savENRG™ -10F Freezer-Packs to provide a total hold-over 6650 BTU capacity. The units were first charged to solid state by keeping them for 24 hrs inside the -20°F flash freezer. Fully charged, they were placed horizontally in the space below the pans. Clean and recharge Freezer-Packs every 3 to 4 days.

Results

The freezer display case was able to maintain ice cream close to +0°F with only a single compressor in operation. Further, with both compressors online and the COLD BATTERY utilizing savENRG™ -10F Freezer-Packs under the gelato pans, the thermostat setting to switch the compressor “ON” was changed to +5°F. This was done to maintain a soft pull to the ice cream in the display. The compressors cycled less frequently and operated at a lower load. This resulted in significantly lower noise in the store and reduced chances of compressor failure.

Benefits for the franchise owner:

  1. Economical & safe immediate thermal backup to maintain the load at required temperature
  2. Serious reduction in repair and maintenance costs
  3. Significant energy savings
  4. No lost opportunities for sales
  5. Eliminates the need for Dry Ice, along with the associated hazards and risks Dry Ice poses
  6. Reusability factor: Freezer-Packs are reusable for thousands of cycles, not only directly in the Creamery but also for remote catering needs
  7. NSF Certified - THE Standard in Commercial Food Safety Applications

Performance report

Once the results were established, engineers at RGEES, LLC conducted further investigations to determine exact temperature profiles. Three temperature data loggers were installed, one each in the display space above the gelato pans, below the gelato pans and within the compressor air chamber space. The franchise owner established standard operating procedures to clean and recharge savENRG™ -10F Freezer-Packs every Thursday and Sunday night. The operation was run with and without savENRG™ -10F Freezer-Packs.

Graphs above show comparative results. Temperatures maintained above the gelato pan (green line), below the gelato pan (blue line), and in the compressor air chamber (dark blue line) are significantly lower with savENRG™ -10F Freezer-Packs.

Testimonials:

Highly Recommended as Thermal Backup!
"The Cold Battery is extremely easy to handle in my Cold Stone Creamery, and when charged in the blast at -25 degrees it essentially acts as dry ice that can be used over and over again. Additionally, summer of 2016 was the first summer when my compressor worked without failure! That's the saving of few thousand already!"

- Chad Eads, President, Cooler South Enterprises, LLC.

 

Super cold and efficient
"They work amazing and are much better than buying dry ice all the time!

- Josh Cristensen, Cold Stone Creamery & Rocky Mountain Chocolate Factory in Logan, Utah

 

Delivering real financial returns on investments in green, energy efficient technology.

CONTACT US: info@rgees.com