Large National Bakery Distribution Centre: Natural Refrigerant Innovation

The Challenge

A large national bakery required an advanced refrigeration system for a new distribution centre in Newcastle to support its growing operations. The challenge was to design and install a complex multi-temperature refrigeration solution capable of handling spiral freezing at -40°C, cold storage at -26°C, and chill areas at varying temperatures, whilst aligning with the organisation’s commitment to environmental sustainability.
The project demanded the use of natural refrigerants to minimise environmental impact, reduce carbon emissions, and support net-zero objectives. Additionally, the system needed to integrate seamlessly with other building services, deliver precise temperature control for food safety compliance, and incorporate innovative heat recovery solutions to maximise energy efficiency, all within a demanding construction timeline.

The Integral Cooling Tech Approach

Integral Cooling Tech implemented a comprehensive natural refrigerant solution featuring three distinct systems:

• An ammonia (NH3) primary system for spiral freezing with a 575kW design capacity, using inverter-driven Mycom screw compressors with integrated heat recovery.
• An R290 (propane) hydrocarbon chiller providing 252kW of cooling capacity for glycol-based chill areas.
• Subcritical CO2 systems serving cold storage requirements.

The design incorporated advanced energy-saving features, including open-flash economiser operation, variable speed drives on lead compressors, and pre-oil coolers capable of recovering up to 280kW of waste heat for facility heating.

Close collaboration with the consultant and main contractor ensured seamless coordination of mechanical, electrical, and structural interfaces. Weekly progress meetings, detailed method statements, and proactive risk management enabled effective integration with other trades whilst maintaining the project schedule.

Results

The distribution centre project was successfully delivered on time and within budget, with zero health and safety incidents recorded throughout the 12-month installation period.

The natural refrigerant solution achieved exceptional environmental performance. Ammonia was used for primary refrigeration, eliminating the need for approximately 4,200kg of CO2-equivalent synthetic refrigerants. The R290 hydrocarbon system reduced environmental impact by up to 98% compared with conventional HFC alternatives, while the heat recovery system provided 280kW of sustainable heating, supporting the customer’s net-zero ambitions.

All temperature zones achieved and maintained their design parameters from day one, including spiral freezing at -42°C, cold storage at -26°C, and chill areas operating between 0°C and +2°C, ensuring full compliance with food safety standards.

The successful handover included comprehensive training for the client’s engineering team and a three-year maintenance package, establishing a foundation for long-term operational excellence and demonstrating Integral Cooling Tech’s capability to deliver complex, sustainable refrigeration solutions for the food manufacturing and retail sector.