Azanechiller 2.0- Low Charge Ammonia Refrigeration

Key features of the Azanechiller include:

  • Variable speed reciprocating compressors
  • High efficiency IE3 drive motors
  • Low profile, air cooled condenser with high efficiency
  • EC condenser fans and epoxy coated fins as standard
  • Compact plate and shell evaporator with integrated separator
  • PLC control to continuously optimise chiller operation
  • Remote PLC access facility
  • Continuous performance monitoring and optimisation
  • Factory charged, run tested and commissioned prior to dispatch
  • Options for:
    • Single or twin compressor
    • Axitop for all condensers
    • Heat recovery
    • Witnessed performance test at factory

Refrigerant type

Ammonia is produced by biological processes, is naturally decomposed, and does not add to the global greenhouse effect.

The Azanechiller is ideally suited for cooling applications including:

  • A future proof chiller solution which does not fall under the F-Gas regulation
  • A chiller that has an efficiency 71% higher than the Eco Design Requirement
  • An SEER of 5.60 for comfort cooling applications and an SEPR of 7.59 for process cooling
  • Refrigerant charges of 0.18kg/kW
  • 39% reduction in chiller weight
  • 15% reduction in footprint
  • No plant room required
  • 20+ year life expectancy
  • A quick installation
  • A chiller that is ready to run when delivered to site

Azanechiller 2.0 Case Studies

  • Gist Chesterfield


    Star Refrigeration has completed the design, supply, installation and commission of one of the most efficient chillstore plants in Europe to serve supply chain company, Gist’s, midlands-based temperature controlled logistics site.

    The plant was required for Gist’s new depot at Chesterfield, near Sheffield and needed to be installed on a tight timeframe, with impressive environmental credentials and low energy costs. Star is pleased to have delivered on all fronts, bringing the plant online ahead of schedule, at a competitive cost and low running costs.

    Chilling Britain’s food now and in the future

    As one of the leading temperature controlled logistics companies, Gist handles, stores and transports millions of chilled and frozen food products every day. 

    Gist’s UK-wide network of temperature controlled logistics sites are responsible for managing the supply chain for a wide range of customers in the food industry, including retailers and food service outlets. To support business growth and their customer partnerships, Gist opened a new chilled depot in Chesterfield, serving their midlands-based customers.

    The project brief required a cooling solution that:

    1. Used an ultra-efficient and environmentally friendly, future-proof refrigerant,
    2. Delivered low greenhouse gas emissions via 'indirect emissions' linked to the chiller's power consumption, which in turn would reduce operating costs,
    3. Eliminated ‘direct emissions’ which are associated with refrigerant leaks and counteracted by the EU's F-Gas Regulation,
    4. Had built in redundancy to deliver continuous cooling, increased efficiency and low operating costs.

    Gist’s ambitious installation has a great impact on cutting both direct and indirect carbon emissions and supports with Europe's objectives of reducing carbon emissions.

    Combining high efficiency and low environmental impact

    Working to Gist’s specification requirements, Star’s proposal was to install two of its Azanechillers, connected to a central glycol cooling circuit, with 11 off-air coolers inside the chillstore chamber. Both Azanechillers were required to have a capacity rating of 550kW, delivering a total capacity of 1,100kW based upon a chamber temperature of +2°C and a design ambient temperature of +32°C. Waste heat recovery from the chiller’s compressors would be used for warm glycol defrosting of the air coolers.

    This solution would deliver an estimated 153% of the calculated maximum cooling requirement, and only require three of the four compressors to maintain temperature at the required conditions. The additional chiller and cooler capacity would be used at all times to deliver increased efficiency and low operating costs. Taking into account these factors, and a reputation for delivering low cost of ownership ammonia solutions, Gist awarded the contract to Star on the condition that Star were able to deliver the fully operational chiller within the required timeframes.

    In addition, in order to ensure the plant would perform as per specification, Star’s Azanechillers 2.0 and air cooler electrical panels included power meters that continuously record energy consumption and send this data to the refrigeration system’s supervisor PLC. Since its installation, energy consumption has been collected on a weekly basis from Star’s Derby office via the chillers remote connection facility and analysed based on the known store volume (58,500m3) to calculate the energy consumption per m3 of store volume. This data has then been compared to energy usage data collected as part of an International Institute of Refrigeration (IIR) and ETSU best practice and demonstrated a consumption that is 15% of industry average for a store of this volume (5 kWhr/m3/yr vs 40 kWhr/m3/yr, respectively).

    Helping to deliver Christmas for British households

    Gist required Star to supply, install and commission the chillers by the 17th November 2017, six weeks after the commencement of the site installation. This is half the time typically expected for a project of this scale. In order to realise this ambitious timeframe, Star worked closely with the main contractor and other subcontractors onsite to co-ordinate installation works.

    Despite the tight timeframes, Star completed the project ahead of time and helped to ensure Gist were able to add capacity to their network ahead of their busy Christmas peak period.

    This achievement was made possible by Star investing heavily in the design stage of the project. Time and resources were spent in prefabricating cooler valve sets and pipework brackets at Star’s Thornliebank manufacturing facility, to minimise the amount of onsite work required at Gist Chesterfield. The chillers, which incorporated warm and cold glycol pump skids, were charged with ammonia and commissioned using Star’s 1MW test facility at their Westway production facility before delivery to Gist Chesterfield. This reduced the site-based work required to install the coolers and secondary pipework. The cooling system controls were also tested by Star’s Telstar team in Glasgow prior to installation at the site, reducing the time required to commission at site.

    The above factors, coupled with meticulous planning and plenty of hard work, ensured that the project was delivered safely, within the allotted budget, before the deadline and to the client’s expectations.

    All-Star performance – The Outcome

    Gist’s Azanechillers 2.0 exceed the ‘Minimum Energy Efficiency Requirements’ set by Europe’s Ecodesign Directive by 56%.

    The plant has now been fully operational for a year and readings from the site indicate that the energy usage is around 5kWh/m3 per yr. This is equal to one eighth of that of good practice guidelines and one twelfth of typical cooling demands for similar stores across Europe, bringing the 60,000m3 facility’s annual energy bill to just over £29,000 and its CO2 emissions to under 83 tonnes/year.

    With UK average grid carbon readings of 283 grams of carbon dioxide equivalent per kilowatt-hour, Gist Chesterfield is now set to remove 943 tons of CO2 per year when compared to the typical cooling demand of similar European chillstores. Gist Chesterfield now has one of the most efficient plants in Europe and one that is future-proofed against any legislation that the EU or the UK may introduce going forwards as ammonia has zero detrimental environmental effect on ozone depletion or global warming. In addition, the Azanechiller 2.0 also eliminates the risks associated with refrigerant leakage.

    Sam de Beaux, Gist’s Engineering Director, responsible for Gist’s UK and European site network, said, “Star delivered above and beyond our expectations regarding every aspect of the Gist Chesterfield plant, providing a solution that combines both high efficiency and low environmental impact. Despite the tight timeframes for the installation and commissioning of the chillstore facility, Star delivered every step of the way. We look forward to a long and fruitful relationship working with them in the future.”

    The original contract included a two-year warranty period at the Gist Chesterfield site, during which time Star would undertake all maintenance and cover the cost of parts and labour. However, thanks to their impressive performance, Star have subsequently been contracted for further maintenance work at Gist’s sites in Hemel Hempstead and Bristol. This signals a mutually beneficial partnership between the two companies going forward.

     


  • Snozone Milton Keynes


    Snozone provide the UK’s leading snow centres for indoor skiing and snowboarding on real snow. Snozone’s two indoor snow centres, located in Milton Keynes and Castleford, offer skiers and snowboarders an authentic slope experience. The facilities suit first time skiers or experienced snowboarders, and have taught nearly 2 million guests since opening in 2000.

    The facility in Milton Keynes has a run 170m long is maintained at -4C air temperature and contains 1500 tonnes of Snow and Ice.  The cooling system provides low temperature glycol for circulation in pipework under the slope, to air coolers in the room and snow guns to maintain the Alpine environment for the customers enjoying their winter sports.

    The facility is also an anchor tenant in the purpose built Xscape leisure and retail complex and is a key attraction in Milton Keynes which celebrated its 50 year inauguration in 2017.

    Snozone contacted M&E Building Services Consulting Engineer, Hulley & Kirkwood, to help them with problems they were experiencing with the refrigeration system.  In recent years the plant was becoming more unreliable and was having difficulty coping with Summer ambient temperatures.  This resulted in problems with maintaining temperatures in the snow chamber and meant that temporary chiller plant was required on a seasonal basis to augment cooling from the R404A chillers installed in 1999. 

    The striking architectural line of the Xscape roof structure mean that all building services were located inside the building with air intakes/ outlets taken through the perimeter walls.  The plant comprised 2 x 100% primary circuits with screw compressors and shell and tube evaporators inside the machinery room.  Heat rejection equipment comprised air cooled condensers located in a dedicated chamber and air blast oil coolers also in the plant room.   The secondary refrigerant system pumps glycol through the chillers to 16 coolers mounted in the roof of the ski slope and to the underfloor pipe grid.

    The screw chillers were rated for 360kW at -16C glycol off temperatures.    As the original manufacturer, Tri-Therm are no longer in business the plant was being maintained by a local contractor.

    For this reason, it was difficult to obtain information about the plant so site surveys and some original drawings provided some background data.

    The customer decided to invest in a future-proof, brand new refrigeration plant and since they had good experience using ammonia at their other location in Castleford, they sought to use this refrigerant at Milton Keynes.

    The existing plant room was unsuitable to retrofit a new ammonia plant so the decision was taken to locate the new system outside.  A site survey revealed that it was impractical and costly to install the chillers in the car park so a location was chosen on the public thoroughfare outside the existing plant room.  This location offered short tie in connections for power and glycol but also allowed improved airflow for the new chillers and  the ability to create a secure compound.

    It was recognised early in the project that it would be necessary to engage a specialist consultant to conduct an Ammonia Hazard Assessment to identify all safety measures required for installation of the new outdoor refrigeration system. Star Technical Solutions (STS) attended site and specified a number of project enhancements for the safety of building employees and the general public.

    • Secure compound which did not obstruct fire exit stairway
    • Relief valves piped to a dispersion tank sized to absorb any ammonia releases
    • Ammonia gas detection sensors on both chillers tie back to a building alarm system
    • Alarms to isolate air intakes in the vicinity of the chillers
    • Delivery of ammonia awareness training to Snozone staff

     

    H&K arranged for planning approval for the new external plant.  Noise surveys were taken before and after the installation to prove it was no worse than the existing installation to the surroundings, particularly considering a new hotel was being built across from the facility.

    Liaison with the Landlord and affected tenants was also a key consideration to minimise the impact of the refrigeration upgrade during and after installation.

    Continuity of business was extremely important to Snozone.  Not only did they want to avoid any loss of skiing amenities for their customers, they could not afford to have any sustained cooling outage as it would result in loss of their ski slope and possible adverse release of water into the centre’s shopping and restaurant outlets.

    The location of 2 off 9.7m long chillers on the paved area outside the plant room required careful survey to ensure that they did not obstruct any underground services or impact on traffic movement or parking adjacent on the site access road.  A louvered perimeter wall was specified to screen the chillers from public access that also allowed adequate air flow onto the air cooled condenser coils.

    Break ins to the glycol system were made in advance of the chillers being installed to provide secure isolated connection points for the new interconnecting piping between cooling plant and chillers.  The piping was carefully routed to ensure one of the existing chillers was useable for as long as possible before being decommissioned. 

    A Programme was prepared to manage overall works and the changeover from new Star chiller from hire chiller was achieved without any cooling outage.

    The original hydraulic circuit was arranged to circulate 50% of the flow through one running chiller which cooled from -10 to -16C and then mixed with 50% bypassed flow to achieve an aggregate glycol temperature of -13C pumped to the ski-slope.  The upgraded system was designed to circulate full flow through 1 chiller giving a glycol off temperature of -13C for improved efficiency.

    The new installation included 2 off Star AA415MTE-1 Azanechillers 2.0 rated for 360kW capacity chilling ethylene glycol to from -10 to -13C.  The chillers were equipped with Sabroe reciprocating compressors with flange mounted VSD electric motors allowing capacity control down to 17% load.  Vahterus plate and shell evaporators allowed a close refrigerant approach while minimising ammonia charge to only 85kg per chiller.  Acoustic enclosures around the compressor/motor assembly combined with EC condenser fans to present the lowest noise signature for the retrofit installation.

    The new chillers have been operational since September 2017 and the effect has been transformational for site.

    The new equipment has been easily able to maintain -13C glycol temperatures in the ski slope even on warmer days, whereas the previous equipment was struggling to achieve -8C at peak times.

    Reliability of the installation is enhanced with a full 100% standby chiller available and no need to bring in hire chillers due to down time with original R404A chillers.

    Energy savings have been dramatic.  The table below shows monthly energy bills before and after the plant was changed over including refrigeration, pumps, lighting, electric defrosting and chairlifts. In the first 4-month period of operation, the electricity usage was 661,255kWh compared to 1,511,062kWh for the same period in 2016.  This 56% saving improved the profitability of the business and helped to justify the investment in new plant.

    The environmental impact of operations has been much improved with almost 700 tonnes of CO2 saved in indirect emissions from electricity in the initial 4 months running and saving of approximately 30kg of R404A per month for top up refrigerant on the old plant.

    Given the uncertain future of HFC refrigerants, the chosen ammonia chiller solution offered a high integrity industrial plant with 20 year life and was future proof with no risk of phase out in future.  This also allowed Snozone to fund their investment over a longer term in line with their financial targets.

    Better operation control of cooling has allowed Snozone to manage the snow environment in the chamber and to optimise snowmaking and defrosting activities for an improved customer experience.  On their company website Snowzone advertised “ they now have a £1m investment in new chillers and have the best snow ever!”


     


  • Stirling Curling Rink - UK’s first National Curling Academy


     

    Star has been working in the leisure industry since 1970, installing 80% of the UK’s ice rinks, curling rinks, indoor ski slopes and ice walls, including Braehead Arena where Sochi Paralympics 2014 bronze medallist Aileen Nielson trained for the competition. This experience in delivering high quality winter sports training facilities resulted in the company being approached as a consulting partner in the construction of the UK’s first National Curling Academy.

    Scotland has a long history with curling but surprisingly until recently there had been nowhere in the UK for elite curlers to train. In preparation for the 2018 Winter Olympics and Paralympics, it was decided that a dedicated training facility for curling athletes was to be built in Stirling, as an extension to The Peak sports centre.

    The National Curling Academy at The Peak is launching a bid for gold as Aileen Nielson, captain of the Paralympian curling team, aims to capitalise on her bronze medal from the 2014 Winter Olympics.

    When asked about the new state of the art curling rink Paralympian Aileen Nielson, said, “For me, the quality of ice at the ice rinks I practise at is crucial to enable me to become the best curler I can be. If you have consistent ice then you are able to more accurately analyse your technique and delivery and if the ice is consistent it is one less variable to take into account. It is good to train and practice on different ice conditions but there is nothing better than training on ‘World class’ ice every day in preparation for playing at the major competitions, like Worlds, Olympics and Paralympics where you generally get top quality ice”.

    “I would like to thank Star Refrigeration for their continued support, and all the ice rinks we have used over the years. We appreciate all of the hard work by dedicated staff who are involved in producing top quality ice in order for us to be the best we can be”.

    Robertson Central East was the main contractor for the project but had no experience in ice rinks. As Star Refrigeration had installed the original ice rink at The Peak in Stirling in 2008, the organisation was approached to become the subcontractor and offer expertise and installation to deliver the premium quality ice required for the elite curling rink. Up until now, the elite curlers had to share ice at the ice rink facility before the £3.15 million Curling Academy, funded by SportScotland and Stirling Council, was built.

    Alan Walkinshaw, Special Projects Manager from Star Refrigeration said, “Scotland has always been on the map for curling, yet we have never had a dedicated training facility for our curling athletes to build on their success. This exciting development means that the UK’s curling teams can train all year round in the high quality facility to help them reach the top of their game – and hopefully bring back more medals!”

    As an extension of The Peak, the curling rink is a standalone building adjacent to the sports complex. Star was required for the design, supply, installation and commissioning of a packaged refrigeration unit and glycol pump assembly. Engineers designed and installed the curling rink floor and interconnected warm and cold pipe circuits. Having never built an ice rink, Robertson Central East needed to work with a trustworthy and reliable contractor with experience in ice facilities.

    David Cairns, managing director of Robertson Central East, said: “Stirling is Robertson Group’s headquarters so it was a particular pleasure to work on such a major project on our doorstep. The construction phase went smoothly and I’m sure that those who use the National Curling Academy will enjoy the high-quality facility for a long time to come.

    “We specially appreciate our partnership with Star Refrigeration. Their exceptional knowledge and vast experience in the leisure and ice market were fundamental to delivering a highly efficient, low carbon, first class facility on time and budget”.

    Star suggested the use of an air cooled package with Azanechiller 2.0. The equipment selection was ideal for the project because there was no need for a large chiller plant room, and the natural refrigerant meant it was an energy efficient, eco-friendly option as well as future proofed against the F-gas regulation.

    The EcoDesign compliant National Curling Academy’s Azanechiller 2.0 breaks energy efficiency standards with a Seasonal Energy Performance Ratio (SEPR) of 4.28, which is 66% higher than the Minimum Energy Performance Standards set by the Eco-Design Directive. The EcoDesign Directive has the potential to save end-users millions of pounds on energy bills and will have a great impact on cutting carbon emissions to achieve Europe's 80% carbon reduction targets by 2050.

    The National Curling Academy’s Azanechiller 2.0 offers a coefficient of performance (COP) which is 62% higher than competing HFC screw chillers and 42% higher than alternative low carbon refrigerants. In terms of the impact on carbon emissions and life cycle costs, this results in a 700 tonne and £241,000 saving respectively after 20 years.

    The Scottish Government Minister for Public Health and Sports, Aileen Campbell, said, “As our Paralympic curling team competes in PyeongChang, they go with the confidence of having had a high quality preparation in world class facilities, and that they have given themselves the best chance of success. This is thanks to the support and hard work of the National Curling Academy and Star Refrigeration.”

    “Scotland is committed to sport being accessible to all, and seeing our para athletes compete on the world stage is powerful inspiration to anybody who wants to participate and achieve their goals.”

    This joint project has had a transformative effect on the training facilities for elite curlers, who now have their own dedicated facility for year round practice. We wish them the best of luck in PyeongChang!


  • East Kilbride Ice Rink


    Star Refrigeration is helping one of Scotland’s most-loved ice rinks to improve both its service to skaters and curlers and its environmental credentials by replacing their existing R22 refrigeration system with an eco-friendly and highly efficient Azanechiller 2.0.

    The natural cooling contractor’s latest Azanechiller 2.0 will provide East Kilbride Ice Rink with a solution that will significantly reduce the rink’s energy costs and environmental impact which avoids the uncertainty of synthetic refrigerants caused by the F-Gas Regulations.

    East Kilbride’s famous ice rink is currently undergoing complete replacement in order to bring the facility into the 21st century. Originally inspired by Houston’s The Galleria shopping mall, the ice rink attracts between 115,000 and 120,000 visitors through its doors every year. Playing host to a wide range of events, from curling to ice skating parties and even family days out, the rink is very much a fixture in locals’ lives and requires a strong, reliable backbone to support it into the future.

    Star Refrigeration’s expertise in the specialist field of ice rink design and installation helped the company succeed in securing the project following a competitive tender. Having designed and installed a significant majority of the permanent ice rink facilities in the UK leisure industry for the last 45 years, including the original ice rink in the shopping centre, helped demonstrate that Star were the right choice for the job.

    Gerry Campbell, the General Manager of South Lanarkshire Leisure and Culture said, “After a long and productive partnership with Star, SLLC are delighted that they have been selected to provide so much of the fundamental equipment at the newly refurbished East Kilbride Ice Rink.”

    “The new ammonia based chiller system with its significantly improved energy consumption will be an essential part of our successful operation.”

    “The excellence of the service received over the past 25 years from Star ensures we can look forward to the next years comfortable in the knowledge that the single most important piece of equipment will be well installed and well maintained.”

    The refurbishment project includes the removal of existing floor, plant and barriers, and the supply and installation of a new ammonia air cooled chiller, pump set, ice rink floor, barrier system, curling stone storage area, interconnecting pipework and wiring.

    The Azanechiller 2.0 is an air-cooled, packaged ammonia chiller which incorporates energy saving technology and delivers cooling efficiencies that are 71% higher than the EU’s EcoDesign Directive’s requirements and 20% higher than competing high efficiency chillers. In addition, the use of ammonia, a natural occurring refrigerant with zero ozone depleting and global warming potential, will keep the rink in line with current regulations which have banned the use of R22 due to its ozone depleting potential.

    The installation works are being carried out in conjunction with the main contractor’s larger redevelopment of the area around the ice rink, within the Olympia Mall. In order to facilitate a successful and timely delivery, Star’s engineering team scheduled the removal of the existing floor during the night, which allowed for the other works to continue without disruption. Star Refrigeration have a vast experience working in collaboration with main contractors, with ice rinks being a key specialist sector, which proved to be fundamental for this project as the contractor required to be fully reliant on Star's expertise to execute the new ice rink facility and guarantee a successful delivery.

    The standalone air cooled modular Azanechiller 2.0 AA415MT-2 model is part of a specifically designed MT range for medium temperature applications with two compressors to provide extra resilience, and will be installed with run/standby pumpset. The total installation offers numerous benefits, including reduced energy consumption, low maintenance requirements and the advantages of using a zero GWP refrigerant, which future proofs the ice rink against new environmental legislation. The Azanechiller also offers proven exemplary safety credentials and reliability, reduced life cycle costs when compared to the next best alternative, and a long life expectancy of over 20+ years.

    Lewis Brown, Business Development Manager for Star Refrigeration who is overseeing the project through from its inception, said, “East Kilbride ice rink’s state of the art Azanechiller 2.0 has a Seasonal Energy Performance Ratio (SEPR) of 4.32, which is 71% higher than the EU EcoDesign Directive requirement.”

    “Our research showed life cycle cost savings of £278,000 and carbon savings of 1,204 tons of CO2 over 20 years for this specific application when compared with ‘best in class’ ammonia screw chillers.”

    Star Refrigeration has long ties with East Kilbride ice rink, having installed their previous system – which lasted 26 years and operated round the clock – when it was first opened in 1989. The rink is also located just 10 minutes away from Star’s head office and manufacturing facility with in-house design team in Glasgow. This is a welcome extra layer of assurance for the ice rink which will have a dedicated, fully qualified engineering team readily available 24/7.

    The installation is expected to be completed by the end of the year. Star Refrigeration’s local Bellshill branch will continue to offer support through a three year maintenance programme to ensure the ice rink performs at optimal design conditions. 


  • Sabic UK Petrochemicals


    As Europe’s leading producer of petrochemicals, SABIC UK demands the highest quality equipment on the market. This ensures that the product is of exceptional quality, as well as enforcing the safety of staff and site visitors. 

    The RBS Butadiene Plant in Wilton is one of SABIC’s 13 world class petrochemical production sites. The company’s existing refrigeration plant is 35 years old and in order to replace and bring it into line with the R22 phase out, which came into force last month – January 2015 – SABIC recruited Star Refrigeration.

    After preliminary consultancy work with STS, a plan was developed to install a bespoke system which completely replaced the existing R22 plant. However, when the total project costs were evaluated, a fully bespoke scheme proved expensive. Star Refrigeration embarked on a mission to produce a lower cost solution using modular package design chillers to meet the process cooling requirements. SABIC trusted Star to keep costs to a minimum and ensure a smooth transition to efficient and low carbon refrigeration systems.

    Jon Hetherington, SABIC Project Group Manager said, “After reviewing the initial total replacement plan, we decided that the costs were simply too high. We started to look for alternative solutions and Star’s modular package project looked attractive. As well as using premium quality equipment, the company enjoys a strong industry reputation which gave us confidence that we were working with one of the most reliable suppliers in the business.”

    As part of the upgrade, Star installed 3 off 193KW ammonia Azanechillers to cool 40% w/w ethylene glycol from –9oC to –14oC. The air-cooled Azanechillers are configured to operate in series for maximum efficiency, actively cooling the glycol supplied to the butadiene process heat exchangers.

    For SABIC, this innovative approach represented a range of benefits. One of the major benefits was the significantly lower cost compared to initial quotes for a fully customised system. The new modular design of the Azanechiller offers improved efficiency and reliability, while the first rate equipment immediately boosts the longevity of the plant, as does the low change ammonia technology employed.

    The use of natural refrigerant ammonia has also future proofed the Wilton RBS Butadiene Plant and brought it into line with governmental law. The conscientious decision of using natural refrigerants cements the company’s status as a responsible manufacturer of “the chemistry that makes things possible.”

    While this particular project was unique, it wasn’t the first time that Star has worked with SABIC. The leading industrial refrigeration and heating supplier has previously supplied a propylene refrigeration system for the SABIC Ethylene Liquefaction Plant at North Tees. The project was a great success, which gave SABIC reassurance that they were enlisting the help of a tried and tested company. 

    Star is currently offering SABIC a three year maintenance contract, which will ensure that the new modular design Azanechiller system continues to perform at its best. 

    In the future, Star hopes to continue to work with SABIC UK Petrochemicals and help the company to maintain its status as Europe’s leading polyethylene and polypropylene business.


  • Farmfoods


    Star Refrigeration has completed a major cooling project in partnership with frozen food specialist Farmfoods, for their new distribution centre in Avonmouth. Farmfoods originated in Aberdeen in 1955 and now operates around 300 stores in the UK. The new distribution centre in Bristol will supply the southern retail stores as a result of a review of their distribution operation.

    Farmfoods were looking for a modern and efficient refrigeration system using a natural refrigerant to compliment their existing distribution centres. Following a competitive tender process Star Refrigeration was chosen for the project and designed an energy efficient and environmentally conscious refrigeration package using their Azanechiller and Azanefreezer units. These were chosen due to their simplicity and exceptional efficiencies across a wide range of operating conditions.

    The installation comprises of two modular coldstore packages with the capability to add a third package in the future and a modular chillstore package with spare refrigeration capacity to accommodate future additional load.

    The coldstore packages utilize waste heat recovered from the refrigeration systems to heat a glycol underfloor heater mat contained within the coldstore floor slab. They also use Star's patented Reverse Cycle Defrost (RCD) valve ensuring quick efficient defrosts within the coldstore without the need for any additional electrical heating.

    James Ward, Star's Director of Food Sales says: "The Azanechiller offers a significant increase in performance compared with standard HFC chillers. Its packaged design and careful component selection result in an ultra low refrigerant charge, with all ammonia contained within the chiller and outside the production facility. This means a refrigerant charge as little as 0.1kg per kW."

    The system includes a 2 year warranty as well as a 5 year preventative maintenance programme. Both the coldstore and chillstore systems have remote dial in/out access and the maintenance package includes a number of condition based monitoring techniques such as vibration monitoring, thermographic scans and oil sampling.

    The total installation offers numerous benefits including low maintenance and reduced energy consumption, as well as the environmental advantages associated with ammonia as a natural refrigerant. Other benefits include:

    • Modular design - "Plug & Play"
    • Small footprints
    • No plant rooms required
    • Low total cost of ownership
    • Low maintenance costs

    Star developed the Azanechiller and Azanefreezer range of ammonia packages to meet the cooling requirements in a wide range of markets. Suitable for cooling direct refrigerant, water and glycol, these packages are ideally suited to applications in food processing, temperature controlled storage, building services and process cooling.


  • Kuehne + Nagel, Wellingborough


    Star Refrigeration completed a £1.4M cold and chill store project for global logistics provider Kuehne + Nagel.

    Star designed and installed a high efficiency ammonia refrigeration plant at one of the company’s national distribution centres in Wellingborough, Northamptonshire.

    The distribution centre carries out, among other operations, food and beverage logistics for leading UK food service operators. Kuehne + Nagel undertakes supply chain management for the distribution of frozen, chilled and ambient products via the UK road network.

    Working to a strict time schedule and within the space constraints of an existing warehouse building, Star delivered a turnkey cooling solution for Kuehne + Nagel. Operating on natural ammonia refrigerant, Star’s compact dual purpose system supplies cooling to new cold and chill store areas, with 17 vehicle loading docks.

    Star Refrigeration Sales Director Rob Lamb says: “As the UK’s largest independent industrial refrigeration specialist, Star was able to deliver on time within a tight 23-week installation programme. Our previous experience in the cold storage and distribution sector with the project’s main contractor Fitzpatricks also enabled us to meet the target delivery date.”

    Star’s refrigeration plant has a cooling capacity of 500kW for the cold store area, which operates at minus 25 degrees centigrade. The chill store area operates at a temperature of plus two degrees centigrade, maintained by 650kW of cooling capacity.

    The system comprises a two stage pump circulation ammonia plant, with hot gas defrost to the evaporators. As an environmentally conscious natural refrigerant with zero global warming and ozone depletion potential, ammonia overcomes concerns over HFCs.

    The compact and highly efficient system features two low and two high stage compressors, a high stage surge drum and two evaporative condensers. The innovative design offers Kuehne + Nagel running cost savings of £50K per annum compared to a conventional pump system.

    The low maintenance plant features Star’s TELSTAR computerised control system to monitor running conditions and optimise efficiency. The system has remote access via a built-in modem, with a direct link to Star’s 24/7 call out facility.

    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.


  • 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.


  • Scotbeef


    Meat processor Scotbeef has chosen a high efficiency cooling system from Star Refrigeration for a factory extension at its facility in Stirling.

    Scotbeef is a major supplier of Aberdeen-Angus, Scottish beef and lamb products to supermarkets in the UK and across the European Union. The company was recently looking to extend its existing processing site at the Bridge of Allan, in Stirling.

    An energy efficient refrigeration system was required to provide cooling to three new beef processing rooms within the extended facility. It was vital that the cooling system provided accurate temperature control to a post slaughter chill area, beef quarters chill room and boning room.

    Scotbeef opted for a high efficiency ammonia packaged Azanechiller from Star Refrigeration to meet its cooling requirements. The client had visited Star’s manufacturing facility at Westway, near Glasgow, to see the Azanechiller in operation and was impressed by its build quality and low noise levels.

    Star’s Azanechiller is a complete refrigeration package, ideally suited to food and drink production, cold storage, distribution and process cooling. It offers exceptional operating efficiency and has a robust construction designed to provide over 20 years of hassle-free performance.

    Star was responsible for the design, supply, installation and commissioning of Scotbeef’s aircooled Azanechiller, including pumps with variable speed drives, six ceiling mounted glycol coolers and a computerised control system.

    Scotbeef’s low charge ammonia Azanechiller is a central pumped glycol system with a total cooling capacity of 365kW. The unit is fully packaged and located externally.

    Suitable for cooling both water and glycol, Azanechiller was developed by Star for environmentally conscious end users. Ammonia is a naturally occurring refrigerant with zero ozone depletion potential and zero global warming potential. Each unit is pre-charged and factory tested ready for fast installation.

    Star Refrigeration Key Account Manager Grant Buchanan says: “Azanechiller typically offers a 30% increase in performance compared with standard HFC chillers. Its packaged design and careful component selection result in an ultra low refrigerant charge, with all ammonia contained within the chiller and sited outside the facility.”

    He adds: “As a complete refrigeration package, Azanechiller is easy to install. Only an electrical supply and flow/return pipework is required to provide cooling. This cuts down site installation and commissioning time, whilst also avoiding the need for a plant room.”

    Azanechiller is available as an air-cooled or water-cooled unit with cooling capacity from 200kW to 850kW. Azanechiller features high quality, industrial components to offer unrivalled performance, reliability and low maintenance.

    Each unit includes two screw compressors, low noise drive motors, a low charge, low pressure receiver and semi-welded PHE evaporator. Star’s Telstar computerised control system ensures optimum performance, with HMI touch screen interface and broadband connection available for offsite remote monitoring.

    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.


  • Kuehne+Nagel, Brinklow


    Global logistics specialist Kuehne+Nagel has invested in another environmentally efficient chill store cooling system from Star Refrigeration.

    Kuehne+Nagel required a new refrigeration plant as part of an extension to a chilled storage facility at its Brinklow site, near Milton Keynes. The distribution centre handles food and drink logistics for one of the UK’s leading supermarket chains.

    Following the success of previous cooling projects at other UK sites, Kuehne+Nagel approached Star to design and build an environmentally conscious, robust and reliable refrigeration plant for the new chill store. Star worked in partnership with the main building contractor for the expansion project to deliver a turnkey cooling solution for Kuehne+Nagel.

    A world leader in cooling and heating system innovation, Star designed and built a high efficiency refrigeration plant incorporating two of its Azanechillers. The compact ammonia packaged chillers supply cooling to the new multi temperature chill store, with a 56,000 sq ft chamber for chilled goods and a 45,000 sq ft produce chamber for fresh fruit and vegetables. Each temperature controlled chamber has a throughput of around 30 tonnes per hour.

    Star combined the new Azanechiller system with an existing refrigeration plant to give Kuehne+Nagel the flexibility to operate the two chambers within the new chill store at different temperatures. The existing plant allows the fresh produce chamber to operate at +9°C, with the new Azanechiller system enabling an operating temperature of +2°C in the chilled goods chamber.

    Working to a strict time schedule, Star pre-commissioned and performance tested the Azanechiller system at its Glasgow manufacturing facility to reduce installation time on site at Brinklow. Group company Star M&E Solutions was awarded the role of mechanical and electrical contractor, including main low voltage panel works, lighting for the two chambers, fire alarm and alterations to the ventilation system.

    The Kuehne+Nagel system features two air-cooled Azanechillers with ammonia as primary and glycol as secondary refrigerant. Each unit has a cooling capacity of 400kW and features a low ammonia charge of less than 0.45kg/kW. The Azanechillers are located externally, mounted on concrete plinths adjacent to the existing plant room. As an environmentally conscious natural refrigerant with zero global warming and ozone depletion potential, ammonia overcomes concerns over HFCs. Waste heat from the Azanechillers is recovered for defrosting the evaporators in the new and existing refrigeration plant.

    Azanechiller is a complete refrigeration package, ideally suited to temperature controlled storage as well as food processing, building services and process cooling. Only an electrical supply and flow/return pipework is required to provide cooling. This reduces site installation and commissioning time, whilst also avoiding the need for a plant room.

    Suitable for cooling both water and glycol, Azanechiller was developed by Star for environmentally conscious end users. Azanechiller typically offers a 30% increase in performance compared with standard HFC chillers. Its packaged design and careful component selection results in an ultra low refrigerant charge, with all ammonia contained within the chiller and sited outside the warehouse or production facility.

    Azanechiller features high quality, industrial components to offer unrivalled performance, reliability and low maintenance. Each unit includes two screw compressors, low noise drive motors, Star’s low charge low pressure receiver and semi-welded PHE evaporator. Star’s Telstar computerised control system ensures optimum performance, with HMI touch screen interface and optional broadband connection for offsite remote monitoring.

    Azanechiller is available as an air-cooled or water-cooled unit with cooling capacity from 200kW to 850kW. Air-cooled Azanechillers feature high efficiency EC condenser fan technology. Water-cooled Azanechillers include a welded plate heat exchanger condenser to minimise refrigerant charge. Both include floating header pressure control, which optimises efficiency at part load conditions and low ambient temperatures.