Standard and bespoke packaged equipment manufacture

Both our standard and bespoke packages are built to industrial standards, using only top quality industrial components from world leading brands to ensure maximum performance with the highest reliability in highly demanding environments.

Our proven, low-risk refrigeration and heating solutions have been used by hundreds of customers in the UK and around the world, and are proven to last, to reduce running costs and save you money in the long-run.

Our standard chillers are a competitive, lower cost solution which offer an average of 30% reduction in energy and carbon footprint than our competitors' offerings. The chillers are built using modular package design chillers to meet a diverse range of customer requirements.

The knowledge and experience gained over almost half a century of successful installations, from design to aftercare, have allowed us to develop the best industrial refrigeration chillers, including design features and components which have been proven through time. The R&D Star carries out in conjunction with our suppliers enable us to develop better and higher efficiency components, ensuring our chillers are the most sustainable available in the market today.

Star standard and bespoke systems are F-Gas ready to protect your investment and brand. They are easy to maintain, remaining efficient over time and providing the performance you require, and built to last a minimum of 20 years to save you the effort and expense needed to replace or upgrade.

 

Contact

Derek Barclay

Production Manager

Related Case Studies

  • Associated Seafoods


    Aging gracefully is never easy, unless you are a good Scottish single malt.  So, we’ll settle for gracefully-ish. With a remarkably ripened appearance, scoured painted components and the original controls systems mounted on slightly aged metal and wooden panels with gauges and cut-outs, Star Refrigeration’s oldest cooling plant might seem a relic from another era to the untrained eye, but the proud owners will tell you a different story.

    A leading supplier of some of the finest seafood caught right on its doorstep, Associated Seafoods has been in business since 1913. Experiencing steady growth over the years, the company now owns a specialist group of seafood companies comprising Moray Seafoods, Lossie Seafoods and GlenIsla Shellfish. The company is internationally recognised for the premium quality of their langoustines, prawns, crabs, scallops, shellfish, and the famous Scottish smoked salmon, The pride of Scotland.

    In 1979, Star Refrigeration provided the company with two refrigeration packages for their cold storage and production facilities located on the Moray Firth coast of Scotland, in Buckie. According to Wikipedia, ‘1979 (MCMLXXIX) was a common year starting on Monday of the Gregorian calendar’, but for Star Refrigeration, it marks an era as this represents the oldest operating plant in Star’s history. And to add a time perspective, here are a few things some of you might remember: Margaret Thatcher was elected prime minister, Sony introduced the ‘Sony Walkman’, YMCA was in the charts and Superman, the movie, had just been released.

    Built to last, each package consists of a single compressor, LPR, four way valve with patented reverse cycle defrost technology, an evaporator and twin circuit condenser. This industrial system is true Star quality through and through. “It’s a great system, it still hits -25 in the cold store”, says Roddy McDonald, Associated Seafoods Maintenance Manager in charge of routine checks to the system.

    “I’ve been here for around 27 years, and the system was already in place when I started. It is always running – 24/7. We worked out that it’s been running for 324,342hours non-stop. When we need to do maintenance work we shut one down and keep the other one running”, Roddy adds.

    The systems initially ran on ozone-depleting R502. Although very common in the 1970s and 1980s, it is now illegal to use HCFCs, and the system has since been converted to non ozone-depleting and low global warming potential refrigerant.  Star Refrigeration was a precursor in the use of natural refrigerants since its inception in 1979, but “ammonia in those days wasn’t as common in food factories. Depending on the size of the plant, there was a break-over point on whether to use ammonia or not” , said Calum McKenzie, Star’s Regional Manager for Star’s service and maintenance branches in Aberdeen and Glasgow.

    With such a long-standing relationship, the two companies have worked together effortlessly as they both grew substantially to become leaders in their respective markets. Calum McKenzie, said, “This is one of the first systems built using the  low pressure receiver. During defrost, refrigerant flow is reversed, with hot gas flowing to the evaporator where the latent head of condensation is used to melt ice formation. This process has now been proven to be an exceptionally efficient way of defrosting and it is used in the most modern and energy-efficient refrigeration systems today.”

    Apart from replacing the cooling fluid with a drop-in refrigerant and replacing one of the evaporators, there have never been any major issues with the system or loss of cooling in almost 40 years.  Roddy McDonald confirmed that “it is basically the same plant, with all the original electrics, Star’s controls system and components. We have not even rewound the motor so it’s still working fairly efficiently”. Reliable refrigeration over the past 38 years have enabled Associated Seafoods to focus solely on what they are best at, allowing it to grow to employ over 150 people in their factory in Buckie alone. 

    Despite running for almost 40 years, Roddy MacDonald is confident Star’s system can keep going for another decade, “as long as it is kept well looked after as until now, it could keep going for another 10 years, easy.”

    The company has a lot resting on its shoulders. The reliability of the plant as well as good aftercare to ensure continuous smooth operation is critical to their business success. Associated Seafoods supplies to the UK’s leading premium food retailers and also ship their produce around the world.  Exporting to 23 countries, including the States, China and Dubai and with a turnover of £15 million per year, the company takes in around 40 tonnes a week of Scottish salmon and shellfish and has recently invested £3 million refurbishing its warehouse.

    “We are hoping to expand in the near future and continue our relation with Star Refrigeration. For me, there’s never been anybody but Star to work with”, said Stuart Gibson, Operations Director of Associated Seafoods.

     


  • Blakeman replaces R404a with eco-friendly ammonia system


    James T Blakeman & Co is a meat wholesaler and manufacturer of the famous “Supreme Sausage.” Recognised as a leading supplier of cooked sausage and meat products to the ready meal and contract cooking markets, the company was searching for a replacement for their existing R404A system, which is being phased out under recent changes to environmental legislation over the next 15 years. 

    Star Refrigeration helped the sausage manufacturing company upgrade their existing refrigeration system, futureproof their factory and increase energy efficiency at their production site in Newcastle-under-Lyme.

    James T Blakeman & Co’s recognition of more climate friendly alternatives that perform to a higher standard was one of the driving factors behind the replacement of R404a – a widely used refrigerant accounting for 46% of worldwide F-Gases – for ammonia, which has zero global warming and ozone depleting potential. 

    With an overriding commitment to reduce energy consumption and CO2 emissions, James T Blakeman was looking to achieve long-term sustainability and at the same time avoid future increases in HFC refrigerant costs, linked to a decline in their availability.

    In conjunction with Starfrost, one of the Star Group of Companies, Star Refrigeration introduced and installed a new inverter driven Glacier GP2 and spiral freezer system which ensures the continued freezing of cooked sausages for James T Blakeman.

    Kevin Moller, Factory Manager at James T Blakeman & Co, said, “The spiral freezer/chiller system features a stainless steel dual conveyor belt around a single rotating drum, with 28 tiers in total. The dual twin belt with additional side guards allows us to process multiple products simultaneously, giving increased flexibility to the processing line. The product belts also have a stainless steel interior panel, which offers a more hygienic, easy to clean solution.”

    “Our spiral system has been designed to maximise uptime and requires minimal ongoing maintenance. In addition, the temperature control and unique airflow is specially designed for our delicate products, such as skin on sausages, ensuring product quality is maintained for our customers.”

    Star Refrigeration and Starfrost offered a turnkey solution for the sausage manufacturer, installing a zero carbon ammonia plant rated at 159kw at - 42°C SST. The product throughput of the spiral is 900kg per hour of cooked sausage, at an inlet of 85°C and discharging of -18°C. One of the key benefits of this upgrade was energy efficiency. The Glacier uses ammonia, which besides being a naturally occurring gas which has zero GWP for a real eco boost, it is a highly efficient and low-cost refrigerant. In fact, it is 25% more efficient than its HFCs counterparts.

    Phillip Blakeman, Managing Director of James T Blakeman & Co, said, “As an existing customer of Star Refrigeration, we already know the company can provide excellent service levels. We have trusted Star with other installations and aftercare solutions, and they have proven to be highly reliable.”

     “We’re very satisfied with the smooth running of the installation and the post-commissioning process. The new solution has offered us security for the future and we feel it has met all the criteria specified.” 

    The food manufacturers’ power reduction requirements were met by installing an inverter to eliminate high spikes when starting the motor. This resulted in energy savings for the Newcastle based meat company. Kevin Fieldsend, Sales Manager – Food at Star Refrigeration, says, “The project with James T Blakeman & Co has been very successful. We replaced their old system with a solid, energy efficient and environmentally conscious solution that will ensure the performance 

    of the production site for at least another 20 years. Star offered a one point of contact solution to cover all their requirements, which resulted in a straightforward and cost effective job.”

    Independent specialist consultants Star Technical Solutions (STS), a business of Star Refrigeration, were the Construction (Design and Management) (CDM) coordinators. 

    STS Director David Blackhurst said, “We are pleased with the overall process. All parts involved delivered on time and on budget. The customer has received a robust solution, which includes site training for operators, as well as Ammonia Hazard Risk Assessment (pre and post project) and Written Scheme of Examination (WSE) to ensure legal compliance of the business.”

    Star Refrigeration’s long-standing relationship with the “Supreme Sausage” manufacturer is down to understanding the strict demands of a company with a reputation for consistent high quality produce. Star have worked with the wholesaler on other projects, including a central ammonia plant serving two more spiral freezers and a single spiral freezer, and maintenance contracts including ongoing maintenance for the new installation to ensure the refrigeration plant remains reliable and efficient.


  • Indigochiller for Air Conditioning


    Forward thinking operators looking for high efficiency, low maintenance air conditioning should only consider a chiller that is built to last, says cooling expert Star Refrigeration.

    Star is renowned for designing cooling solutions that provide over 20 years service. The company is currently seeing a rising number of replacement projects in which standard AC chillers have suffered early component failure or corrosion problems in less than ten years.

    Star believes that environmentally conscious building services operators should consider the chiller’s expected lifespan as a matter of priority, or be faced with a costly problem all too soon.

    Star Refrigeration sales director Rob Lamb says: “We have recently seen a number of high profile operators who have previously invested in chillers that have soon become damaged or corroded. Even if the chiller features high efficiency components, poor build quality can cause early loss of performance or even break down.”

    With growing demand to cut refrigerant leakage to meet F-Gas regulations, Star developed its Indigochiller for medium to large scale air conditioning and process cooling. Engineered to have minimal effect on the global environment, Indigochiller’s robust design aims to eliminate refrigerant leakage and offer over 20 years service.

    Star’s confidence in Indigochiller’s construction and reliability means options are available for extended warranty on both equipment and refrigerant loss.

    Rob Lamb adds: “Indigochiller stands out from the rest of the market thanks to a range of unique design features and leak-tight components. It is manufactured to ensure both long-term reliability and low life-cycle costs. These should be key considerations when selecting a chiller.”

    The low charge, high performance Indigochiller features a revolutionary Turbocor compressor, which is low maintenance by design to ensure lifelong trouble free running. The oil-free compressor operates on electromagnetic bearings and uses the synthetic refrigerant R134a. The system offers reliable performance and requires minimal installation, servicing and maintenance.

    Indigochiller is manufactured from the highest quality components selected to minimise the risk of refrigerant leakage, reduce maintenance costs and enhance operating life. Standard features include ‘leak-free’ bellows seal valves, sealed expansion valves and welded steel pipework. The air-cooled Indigochiller has epoxy coated condenser fins as standard to reduce the risk of corrosion damage.

    Available as an air-cooled or water-cooled unit, Indigochiller has capacity options ranging from 250kW to 1,650kW. A robust PLC control system allows the user to monitor refrigerant charge, running conditions and optimise efficiency.

    Indigochiller is highly energy efficient using only 60% of the energy required by a standard chiller operating on typical load and ambient profiles. This offers end users a significant saving in energy and running costs.

    Star Refrigeration is the UK’s largest independent industrial refrigeration engineering company. Star focuses on the design, manufacture, installation, commissioning and aftercare of industrial refrigeration and HVAC systems.

    Star provides total cooling solutions for refrigeration, air conditioning and process cooling. The company offers a turnkey supply and support package to all users of cooling equipment. Star continues to invest in the development of new products to provide energy conscious cooling systems for the benefit of customers and the environment.


  • Nestle Halifax


    Star Refrigeration has been providing Nestlé UK with refrigeration solutions since 1990 and this strong partnership led to the latest challenge for Star. The challenge was to find a Heat Pump solution for reducing the Nestlé Halifax factories refrigeration and heating energy demands.

    The Nestlé Halifax team had previously completed an energy audit on their central coal fired boilers, the steam distribution and all of the end user heating systems throughout the factory. This enabled the team to clearly identify, grade and consolidate the various end user heating requirements which identified significant design and operational inefficiencies.

    Previously one central coal fired steam generation plant served all of the individual end users, where high grade steam would be degraded to suit the processes. The new concept was to simply heat the water to the desired process temperature and the Star Neatpump would serve to provide hot water to end users requiring 60°C and to preheat those operating in excess of 60°C.

    Nestlé’s global commitment to reduce the environmental impact of its operation, demands the use of natural refrigerants for all new factory process refrigeration equipment. This presented a number of challenges for Star as heat pumps until now had been either HFC dependent, which was not an option, or they had utilised reciprocating compressors which were beginning to show high regular maintenance costs or with screw compressors operating at their limit.

    Star Refrigeration, Vilter Manufacturing Inc (USA) and Cool Partners (a Danish consultancy) formed a collaborative effort to devise a high pressure heat pump solution using ammonia and screw compressors up to 90°C. This enabled Star to comfortably take heat from the 0°C process glycol at -5°C and lift it to 60°C in one stage for heating.

    Their challenge was to utilise a heat pump that drew electrical energy and thereby reduced the load on the proposed replacement gas fired equipment. Alternative solutions such as geothermal and CHP were considered, but the client recognised that these technologies imposed limitations to future land resale and/or development and high annual maintenance charges offsetting the predicated savings in cheaper electricity.

    A key stage for the Vilter/Star/Cool Partners (VSC) team was the establishment of bespoke selection software as it was essential to know how to assess the overall effectiveness of the system. Previous projects had been assessed in terms of COP. This project needed to be COPc for “cooling effect/absorbed power.” In addition, COPh for “heating effect/divided by absorbed power” was required, but the real measure of the heating efficiency is COPhi. This is the total heating capacity divided by the net difference in compressor absorbed power between the design cooling only condensing condition and the heat pump design condensing condition.

    Based on the clients' previously measured heating and cooling load profiles, the analysis showed that to meet the projected hot water heating demands from the ‘Total Loss’ and ‘Closed Loop’ circuits, the selected heat pump compressors would have to produce 1.25MW of high grade heat. To achieve this demand, the equipment selected offers 914kW of refrigeration capacity with an absorbed power rating of 346kW. The combined heating and cooling COP, COPhc, is calculated to be a modest 6.25. For an uplift of 17k in discharge pressure the increase in absorbed power was 108kW, boosting the COPhi to an impressive 11.57.

    Without Nestlé’s commitment to research and logging site energy performance, it would have been impossible to gauge how much can be saved by using the waste heat from the cooling process. Since plant handover in May 2010 Nestlé Halifax are heating around 54,000lts of towns water each day to 60°C, which costs around £10, saving some £30,000pa on gas. By late 2010 site will be utilising a further 250kW of waste heat for their Closed Loop systems and by mid 2011 the demand on all heating systems is set to double.

    Nestlé can save an estimated £143,000pa in heating costs, and 119,100kg in carbon emissions by using a Star Neatpump. Despite the new refrigeration plant providing both heating and cooling, it consumes £120,000 less electricity per annum than the previous cooling only plant.


  • Refrigerant R-1234ze(E)


    Engineers at Star Refrigeration have teamed up with Danfoss Turbocor and Honeywell to develop and test a chiller using HFO 1234ze(E) refrigerant, which has a global warming potential of 7. 

    The chiller is based on Star’s very successful Indigochiller range and uses the new Turbocor TG310 prototype compressor.

    "Working with R-1234ze proved to be quite challenging," said Star’s Group Engineering Director, Dr. Andy Pearson. "We found particularly good performance at part load in lower ambient, where the efficiency was up to 20% better than the original predictions. Across the full range of load and ambient conditions performance was generally better than predicted."

    He added: "The development included some tricky puzzles. Some of the materials used in joints and seals did not perform well so we had to source special o-rings for some of the system components. We also learned that the lower gas density can cause increased pressure losses in some unexpected places, so care needs to be taken when assessing condensers, evaporators and control valves to make sure they are not going to cause excess pressure drop which would negatively affect the chiller efficiency."

    Star worked with Danfoss Turbocor to select R-1234ze(E) as the most promising fluid for this application and then in a three-way development team with Honeywell, who developed Solstice ze (R-1234ze)  for use as a refrigerant, foam-blowing agent and other applications.

    The chiller was comprehensively tested at Star’s chiller factory in Glasgow, including operating in an ambient of 40oC on Star’s 1500kW test rig. Turbocor worked closely with Star during the testing and were able to verify and adjust their control software while the compressor was in operation. This was the first time that Danfoss Turbocor had access to the prototype compressor on a live air-cooled chiller to verify their theoretical calculations and lab tests. The adjustments helped to raise the efficiency of the chiller by a few percentage points.

    Now that the tests are complete, the chiller has gone to its spiritual home – on the Honeywell site at Buffalo, NY where the HFO-1234ze(E) refrigerant was originally developed. The chiller will operate on the base load for the lab air-conditioning system, helping to keep the developers of the next generation of refrigerants comfortable at their work.

    Dr. Rob Lamb, Group Sales Director at Star, said: "This development is part of our long range plan. It allows us to give our customers confidence that we can help them transition to low GWP refrigerants moving forward. As the European F-Gas regulations develop, Star Refrigeration will be prepared to offer our customers a variety of refrigerant solutions."


  • Solihull Ice Rink


    Leading cooling solutions specialist Star Refrigeration has designed and installed a new energy efficient ice rink system using natural refrigerants at the Blue Ice Solihull Rink near Birmingham.

    Star has a proven track record in ice rink systems spanning four decades, having designed over 80 percent of facilities in the UK leisure industry. Star worked on behalf of regeneration specialist St. Modwen on the Blue Ice contract.

    The Solihull ice rink is one of the busiest in the UK, with around 150,000 skaters using the facility each year. The client was looking to replace the rink’s cooling system with environmentally conscious and cost effective solution.

    The existing rink refrigeration plant at the Solihull facility was in excess of 20 years old and operated on HCFC refrigerant R22, which is currently being phased out. The system refrigerant charge was in excess of two tonnes.

    Oil-clogged under floor cooling pipes and frost heave had also caused problems with the existing rink floor at Blue Ice. To maintain a level surface the rink required thicker ice, which increased both the refrigeration load and power consumption of the ageing plant.

    Star replaced the 57m x 26m ice rink floor and installed a new Azanechiller packaged ammonia refrigeration plant to replace the R22 system. Azanechiller operates with a small refrigerant charge (under 200kg) and has a total cooling capacity of 416kW.

    With zero ozone depletion potential and zero global warming potential, ammonia is used to chill secondary refrigerant glycol to -10°C. Glycol is then pumped through a network of cooling pipes embedded in the ice rink floor. The system ensures that the temperature, quality and hardness of the ice remains even and constant.

    Blue Ice Solihull Rink’s General Manager Stuart Cummings says: “The installation of the Azanechiller refrigeration system has proved to be very successful, both in terms of maintaining high quality ice for our customers to enjoy skating on and in the reduction of the related operating costs. Star Refrigeration's professionalism and expertise during the installation proved to be invaluable in ensuring a smooth transition from the old system to the new.”

    Star Refrigeration’s ice rink specialist Douglas Scott says: “As Azanechiller is a self contained air cooled package unit, we were able to locate it externally and avoided expensive building alterations to the existing plant room. The chiller is designed to allow easy internal access, ensuring straightforward maintenance and cleaning. This impacts directly on the lifelong efficiency of the plant.”

    As the Blue Ice Solihull Rink is located close to residential areas, Azanechiller’s compressors and drive motors were enclosed in acoustic housing to achieve low noise levels. The condenser fans also feature inverter controls permitting varied speeds to reduce noise levels and power consumption.

    Azanechiller is a complete refrigeration package, with each unit pre-charged and factory tested ready for installation. It offers exceptional operating efficiency and has a robust construction designed to provide over 20 yrs of hassle-free performance.

    Douglas Scott adds: “Azanechiller is ideally suited for retrofit projects where customers typically have limited space for new plant and need to keep project costs to a minimum.”

    Star developed the Azanechiller range of ammonia packaged chillers to meet cooling requirements in a wide range of markets. Suitable for cooling both water and glycol, Azanechiller is available as an air-cooled or water-cooled unit with cooling capacity from 200kW to 850kW.

    Star is the UK’s largest independent industrial refrigeration engineering company. Star focuses on the design, manufacture, installation, commissioning and aftercare of industrial refrigeration and HVAC systems.


  • Strathclyde University


    Students using the library at the University of Strathclyde in Glasgow are keeping their cool thanks to an air conditioning system from Star Refrigeration.

    The University of Strathclyde was looking to replace an aging refrigeration plant in the Curran Building. The six-storey facility is home to the Andersonian Library, which houses university archives and main collections including books, journals and electronic resources.

    Star had previously supplied an Indigochiller refrigeration plant for cooling in another building on the Glasgow campus. The university was impressed with the build quality and performance of Star’s Indigochiller, which is designed for reliable and highly efficient operation.

    The university’s library had an existing air conditioning plant operating on R22, a refrigerant currently being phased out due to its ozone depletion potential. Engineered to have minimal effect on the global environment, Star’s Indigochiller has a robust design that aims to eliminate refrigerant leakage and offer over 20 years service.

    Star designed, manufactured and installed two Indigochillers on the roof of the Curran Building, each with a 750kW cooling capacity. The chillers cool water from 12°C to 6°C, which is then pumped to air handling units throughout the six-storey building for comfort cooling. The building also houses training facilities for the University of Strathclyde’s National Centre for Prosthetics and Orthotics.

    Andy McWatt from the University of Strathclyde’s Estates Management department says: “In recent years the failure of standard package chillers from other manufacturers had proved both disruptive and expensive for the university. We considered various products featuring the state-of-the-art Turbocor compressor. We found Star’s Indigochiller had the operating efficiency and build quality we were looking for.”

    Star Refrigeration’s Sales and Marketing Director Rob Lamb adds: “Indigochiller stands out from the rest of the market thanks to a range of unique design features and leak-tight components. It is manufactured to ensure maximum efficiency, longterm reliability and low life-cycle costs. These were key considerations for the University of Strathclyde when selecting a chiller.”

    The low charge, high performance Indigochiller features the revolutionary Turbocor compressor, which is low maintenance by design to ensure lifelong trouble-free running. The oil-free compressor operates on electromagnetic bearings and uses the synthetic refrigerant R134a. The system offers reliable performance and requires minimal installation, servicing and maintenance.

    Indigochiller is manufactured from the highest quality components selected to minimise the risk of refrigerant leakage, reduce maintenance costs and enhance operating life. Standard features include ‘leak-free’ bellows seal valves, sealed expansion valves and welded steel pipework. The air-cooled Indigochiller has epoxy coated condenser fins as standard to reduce the risk of corrosion damage.

    With growing demand to cut refrigerant leakage to meet F-Gas regulations, Star developed its Indigochiller for medium to large scale air conditioning and process cooling. Highly energy efficient, it uses only 60% of the energy required by a standard chiller operating on typical load and ambient profiles. This offers end users a significant saving in energy and running costs.

    Available as an air-cooled or water-cooled unit, Indigochiller has capacity options ranging from 250kW to 1,650kW. A robust PLC computerised control system allows the user to monitor refrigerant charge, running conditions and optimise efficiency.

    When it comes to designing energy efficient cooling and heating systems, Star is a natural innovator. Star works with strategic partners across the globe to deliver low carbon, cost saving solutions.


  • Yearsley Logistics, Heywood


    Yearsley Logistics has invested in a bespoke high efficiency cooling system from Star Refrigeration as part of an expansion to cold storage facilities at its flagship distribution centre in Lancashire.

    As the UK’s largest cold storage and logistics company, Yearsley Logistics has 13 sites nationwide including its head office and key distribution facility in Heywood, Lancashire. A recent expansion plan at the site included the construction of two new 57,000 cubic metre cold storage chambers for frozen food.

    A world leader in cooling and heating system innovation, Star was chosen to supply a highly efficient refrigeration plant to deliver cooling for the new cold storage chambers. Star has over 40 years experience in industrial cooling systems for the cold storage sector and is currently providing planned preventative maintenance at the majority of Yearsley Logistics UK distribution sites.

    The bespoke refrigeration plant was designed to provide Yearsley Logistics with over 25 years of reliable service, with the lowest possible total lifecycle costs in terms of energy usage and maintenance. Star engineered and installed a single stage pump circulation plant, operating on natural ammonia refrigerant.

    The plant has a 1.2MW (Mega Watt) cooling capacity and features three 400kW screw compressor package units, each fitted with a high efficiency electric drive motor. The two frozen food chambers are served by a total of eight evaporators, which maintain a constant air temperature of minus 24 degrees Celsius.

    The evaporators operate with pumped circulation ammonia via a surge drum and open flash economiser vessel. The cold store evaporators have a hot gas defrost system, with waste heat rejected to the atmosphere via three air-cooled condensers.

    The evaporators and air-cooled condensers incorporate EC fans with integral variable speed drives. This enables efficient operation and yields significant energy savings particularly during periods of part load.

    The refrigeration plant is housed in a dedicated plant room adjoining the two new cold storage chambers. The plant room has been designed to accommodate an additional refrigeration system to serve a third chamber, as part of a future expansion plan. This includes extending the pumped glycol under floor heating system, which utilises waste heat from the refrigeration plant oil cooling circuit.

    The refrigeration plant is controlled via Star’s fully integrated Telstar touch screen computerised control system. This features intelligent functionality including compressor sequencing, evaporator optimisation, floating suction pressure and load shedding in order to minimise plant operating costs.

    Star worked alongside the main construction contractor for the project. Independent refrigeration engineering consultancy and plant specification was undertaken by Star Technical Solutions (STS), whilst mechanical and electrical contractor Star M&E Solutions (SMES) was responsible for supplying plant control panels, as well as all electrical works on site. The plant is now being maintained by Star’s Manchester branch operations team under an extended warranty agreement.

    When it comes to designing and maintaining energy efficient cooling and heating systems, Star is a natural innovator. Star works with strategic cost saving solutions.