NeoCharge: Maximize Ammonia System Performance for Sustainability

NeoCharge enables Direct Expansion (DX) systems to run without superheat. In traditional flooded systems, the solution reduces recirculation to the lowest possible rate while maintaining high system performance. NeoCharge optimizes the cooling process by improving how the system removes heat and maintains temperatures at low levels, ensuring efficient operation and reliable low temperature environments. In short, NeoCharge is a complete method that turns the tables when it comes to low-charge:

• Reduce energy costs by up to 20%

• Increase cold room capacity by up to 40 % using the same refrigerant charge and maintaining low temperature

• Easy-to-install,  plug n’ play solution

• Compatible with any ammonia mechanical refrigeration system and can be integrated with a variety of components

• Retrofit existing systems or deploy in new-builds

Every refrigeration system relies on a set of core components working together to transfer heat and maintain lower temperatures in a controlled space. Whether you’re cooling a cold storage warehouse, running an air conditioning unit, or preserving food in a commercial freezer, the basic refrigeration process remains the same. Understanding these main components is key to maximizing efficiency, reducing energy use, and minimizing greenhouse gas emissions.

At the heart of any refrigeration system is the refrigeration cycle, often called the vapor compression cycle. This closed cycle involves four main components: the compressor, condenser, expansion device, and evaporator.

• Compressor: The cycle begins as the compressor draws in low-pressure refrigerant vapor from the evaporator. It compresses this gas, raising its pressure and temperature. This high-pressure, high-temperature refrigerant gas is then pushed into the condenser.

• Condenser: In the condenser, the hot refrigerant gas releases its heat to the surrounding air or water—this is the heat transfer stage. As the refrigerant cools, it condenses into a liquid state at high pressure.

• Expansion Device: The liquid refrigerant enters the expansion device (such as a valve or capillary tube), where its pressure drops suddenly. This rapid pressure reduction causes the liquid to cool significantly, preparing it for the next stage.

• Evaporator: The cold, low-pressure liquid refrigerant enters the evaporator coil. Here, it absorbs heat from the air or product inside the cooled space. As it absorbs heat, the refrigerant evaporates back into a vapor, completing the cycle.

This continuous process allows refrigeration systems to maintain constant temperatures, making them essential for storing food, supporting industrial processes, and providing air conditioning. The efficiency of this cycle depends on several factors, including the type of refrigerant used, the design of the system, and the effectiveness of heat transfer and air flow within the unit.

Ammonia is a popular choice for industrial refrigeration due to its excellent thermodynamic properties and low environmental impact compared to many synthetic refrigerants. However, it requires careful handling and precise control—areas where solutions like NeoCharge can make a significant difference by optimizing refrigerant flow and reducing the total charge needed.

Other factors, such as the design of the evaporator and condenser, the quality of the expansion device, and the management of refrigerant flow, all play a role in maximizing cooling capacity and minimizing energy use. Properly designed systems ensure that the liquid refrigerant absorbs heat efficiently, while minimizing losses and maintaining safe, reliable operation.

As the industry moves toward more sustainable practices, reducing the use of synthetic refrigerants and lowering greenhouse gas emissions is increasingly important. Innovations in refrigeration equipment, such as low-charge ammonia systems and advanced control solutions, help operators achieve these goals while maintaining or even increasing system performance.

By understanding the main components and the refrigeration process, operators can make informed decisions about system upgrades, maintenance, and optimization—ensuring reliable cooling, lower energy costs, and a reduced environmental footprint.

NeoCharge Controller

NeoCharge technology, powered by the EKE450, intelligently controls refrigerant flow for optimal cooling performance. As a key component of the overall system, this advanced controller can operate with either a single injection valve or a full evaporator, ensuring flexibility and adaptability. Its plug n’ play design and minimal configuration requirements make installation simple. Plus, built-in safety features guarantee continuous operation, minimizing downtime and maximizing system uptime.

NeoCharge Sensor

NeoCharge’s Heated Sensor accurately monitors evaporator conditions, providing real-time insights into refrigerant quality. This compact and easy-to-install sensor is ideal for system retrofits, enhancing the performance of existing industrial air coolers.

NeoCharge Valves

NeoCharge’s compatibility extends to traditional pump circulation systems (CCR) with the addition of new PWM (Pulse Width Modulation) function modules. These modules can be easily integrated with existing ICF platforms, offering greater flexibility and application possibilities. The system is also compatible with ICM and AKVA valves, further expanding its versatility. NeoCharge can be installed in a wide range of refrigeration units, from small-scale systems to large industrial applications.