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Industrial Refrigeration Energy Audits

In a cold-storage warehouse or a food plant, refrigeration is usually the single largest electrical load in the building — and the one where control strategy, not equipment, holds most of the recoverable saving. Of thirteen Canadian competitors reviewed, one listed industrial refrigeration as an expertise and none explained it.

Where the energy goes

A refrigeration plant spends electricity lifting heat from a cold space to a warm one, and the cost of doing that rises steeply with the temperature difference it has to work across. Almost every worthwhile measure is therefore about narrowing that gap, or about not putting heat into the cold space in the first place.

  • Head pressure. Plants are frequently run at a fixed head pressure set for the worst summer day, all year. Floating it with ambient conditions is often the largest single saving in the room, and it is a control change.
  • Condenser control. Fan and pump staging, approach temperature, and whether the condenser is actually clean. An underperforming condenser raises head pressure on everything behind it.
  • Suction pressure and evaporator control. Space temperature set tighter than the product requires costs energy continuously, and so does an evaporator starved by poor superheat control.
  • Defrost. On a clock rather than on demand, defrost runs when there is no frost to remove — adding heat to the space and then paying to remove it again.
  • Infiltration. Dock doors, air curtains, strip curtains and traffic patterns. Every cubic metre of warm humid air that enters is removed at full cost, and it also loads the defrost cycle.
  • Compressor sequencing and part load. Several machines modulating when one should be trimming.
  • Heat recovery. The heat being rejected is sometimes exactly the heat the building or the process is buying separately.
Why controls come before compressors

A compressor replacement is a large capital decision justified against the plant's current operating conditions. Correct the head pressure, the condenser control and the defrost strategy first, and the operating conditions change — which frequently changes the size of machine the plant needs, and occasionally removes the need for it. Buying first and optimising afterwards means paying for capacity to overcome a control fault.

What the audit does

  1. Separate process refrigeration from building load in the metered data. This is not academic: it decides which programmes the site qualifies for.
  2. Log the plant — suction and discharge pressures, ambient, compressor power, run hours, defrost events — across enough days and enough weather to see the relationships rather than guess them.
  3. Survey the cold envelope and the openings, including dock seals and traffic.
  4. Review the control strategy as written against the control strategy as running. They differ in most plants that have had more than one service contractor.
  5. Rank measures by payback and by what each one does to the others, because in refrigeration the measures interact strongly.
  6. Set the baseline and the verification plan, since the Ontario routes worth having are pay-for-performance.

The eligibility trap worth knowing

Process load is excluded from the EBCx threshold

IESO's Existing Building Commissioning programme requires a minimum 750,000 kWh of annual electricity consumption excluding industrial and manufacturing process load. In a refrigerated facility the process load is most of the bill, so a site that looks comfortably over the threshold can fall under it once the calculation is done properly. That separation has to happen before an application, not during one. See the eligibility gates.

For the refrigeration savings themselves, XLerate is usually the right route where anticipated savings clear 600 MWh a year: feasibility cost-shared at 50%, $300/MWh up to 75% of eligible costs, baseline measured before any change, and payment after the M&V report is approved. Verified 3 October 2026 — sources on the programme index.

What we are not

We are not a refrigeration contractor and we sell no plant, controls or service agreements. Safety, code and mechanical integrity work on ammonia and other refrigerant systems belongs to the engineers and contractors qualified for it, and we refer rather than claim. Our scope is energy: measure it, explain it, rank what to change, and verify it afterwards.

Common questions

Will changing setpoints risk our product?

No measure that puts product at risk belongs in the report, and product temperature requirements are a constraint we take from you rather than optimise against. Where a saving depends on relaxing a temperature, the report says so explicitly and leaves the decision where it belongs.

Our plant is ammonia. Does that change anything?

Not for the energy analysis. It changes who may do physical work on the system, and it means the site has safety obligations that sit outside our scope entirely. We work alongside whoever holds that responsibility.

We have a service contract that includes efficiency checks.

Then ask for the logged data and the head-pressure strategy in writing. A service contractor is paid to keep the plant running, which is a different objective from keeping it cheap, and the two diverge most clearly on head pressure.

Related

Where to go next

Request a proposal

Tell us what is driving the decision

A compliance deadline, an incentive application, a financing requirement, or a capital plan. Tell us which, and we will tell you what you need and what it will cost — as a fixed fee, before any work starts.

If you do not need an audit, we will say so.