Danfoss ADC lab testing helps Haglund improve energy efficiency by 34%

Friday, October 11, 2019
Danfoss ADC lab testing helps Haglund improve energy efficiency by 34%

Highlights

  • Energy efficiency savings up to 34%
  • Tests conducted to EN16825:2016 standards
  • Condition ranges from 30°C to 40°C and 40%-55% RH
  • R290 and R600a refrigerants used

Refrigeration manufacturer Haglund Industri AB wanted to achieve energy efficiency class A. Experts at the Danfoss Application Development Center (ADC) rigorously tested new component packages and reported energy savings up to 34%.

Haglund Industri AB is one of Sweden's leading refrigeration manufacturers. They have produced products in sheet metal for more than 150 years and manufactured quality refrigeration solutions for the restaurant and catering trade for the last 65 years. Key to their success is the company's ability to continually innovate and respond to their customers' changing needs.

Recently, those customers have been demanding ever-greater energy efficiency—to protect the environment and reduce running costs. Haglund wanted to keep their position on the frontline, so they sought to achieve an energy efficiency rating of A on their BRIS 850 commercial refrigerators—while also testing the very latest component technology.

Haglund turned to Danfoss, their manufacturing partner since 1954.  At the Danfoss Application Development Center (ADC) in Nordborg, they found qualified laboratory facilities, designed specifically to help customers test and develop new product configurations—under the expert guidance of specialist Danfoss engineers.

Haglund's Managing Director, Johan Haglund, explains: "Our goal is to manufacture the best refrigeration cabinets in Europe. But we can only claim that with a leading energy rating. That's why we approached Danfoss to find a solution."

Haglund Industri AB

Haglund Industri AB

Manufactured quality refrigeration solutions for the restaurant and catering trade for the last 65 years.

The challenge: Achieve greater energy efficiency without driving up costs

One solution would have been to use thicker and enhanced insulation, but that would have been expensive, requiring new equipment and materials.

Haglund therefore decided to lab test the latest efficient refrigeration components—not least to conform with the strict requirements of the European Commission's energy efficiency clarification.

That's where Danfoss offered our expertise. With four dedicated testing sites around the world, our ADCs provide laboratory-standard equipment for testing and optimization—in a collaborative environment supported by expert engineers.

The solution: A "show don't tell" approach to refrigeration testing

Based on these requirements, we embarked on a cooperative testing process with Haglund at our  purpose built facility in Nordborg, Denmark.

The process consisted of four key steps:

  1. Initial conversations and calculations – where both parties came together to discuss where they could make improvements in theory,  including agreeing how and when tests should be done and to what standards.
  2. Preliminary testing – Haglund supplied Danfoss with a BRIS 850AK refrigerator and a BRIS-850FA freezer. Each unit's performance was initially tested to provide a benchmark for further tests. Each test also included simulated door opening procedures to reflect normal usage.
  3. Optimization testing – Danfoss then changed the compressor, condenser coil, thermostatic expansion valve, and filter drier. In addition, the refrigerant charge and TXV setting were adjusted, and the process was repeated.
  4. Results and next steps – Danfoss discussed the test results with Haglund to identify the best possible configuration for refrigerant charge and energy performance.


Johan explains the tests: "We were really surprised that by using smaller compressors, our refrigerators were still able to achieve the same high levels of performance as before."

Haglund's refrigerators are used in commercial kitchens and need to be compact, movable, and, above all, safe when using flammable refrigerants. That's why, under allowable refrigerant charge regulations for small spaces, the charge had to be kept under 150g. 

By switching to a smaller filter drier and micro-channel condenser, Danfoss maintained this limit and even reduced the charge to 130g in one case.

The results: 34% greater efficiency and 13% reduction in refrigerant charge

Haglund has led the way with low-GWP refrigerants for over ten years—and these tests were no exception. By switching to variable-speed compressors, Haglund's optimized system can now use R600a—saving 34% on energy.

It also means they have proven the refrigerator's credentials in testing—upgrading its energy efficiency rating B to A.

"Now we've managed to reduce refrigeration charge in our units, we can conform to strict safety standards with greater ease. What's more, it has helped open up new markets for us," said Johan.

"We honestly believe our refrigeration cabinets—especially new models—are the best in Europe. We are known to produce products with a high-end quality in our segment. The changes mean our customers save money and it's much better for the environment, too."

Because the process was so collaborative at every stage and achieved positive results, Haglund intends to continue its relationship with Danfoss.

The manufacturer wants to review its entire portfolio of around 150 units to understand how it can further improve energy efficiency—something countless other organizations set out to achieve at our ADCs when they partner with us.

Johan Haglund

"We honestly believe our refrigeration cabinets—especially new models—are the best in Europe. The changes mean our customers will obtain a more developed product, save money, and it's much better for the environment, too."

Johan Haglund,
Managing Director
Haglund Industri AB