Technical Corner

January 9, 2025

Introduction

The cycle of refrigeration will not change – it is the science of the removal and transfer of heat. However, how this will be accomplished has become more technologically advanced requiring more reliance on service contractors and less ability for frontline operators to perform basic maintenance or adjustments. When the ORFA first began to offer educational pathways for ice sheet refrigeration operators, the industry was primarily an ammonia/brine configuration. These systems were “basic” in design, affordable to purchase but expensive to maintain and operate, as brine was corrosive and bulky to move requiring excessive energy to move it through the veins of the system. At that time no one really focused on cost to operate as energy was cheap and replacement parts reasonable.

Monitoring of brine health was not always a priority and that resulted in the pH levels fluctuating reducing life expectancy of the internal organs of the system. In addition, if the brine/water/inhibitor mixture was not properly maintained, it further reduced lifecycle of equipment and added energy costs as the equipment had to operate longer to meet temperature settings that resulted in higher hours of operation which drove up maintenance costs. Introduction of other refrigerants provided options to plant owners to consider but had other operational and maintenance challenges to be tamed.

Senior plant operators would often state “they don’t make equipment like they use to” - meaning the projected life expectancy of key components was dramatically being reduced. Claims of more energy efficient equipment needed to be vetted as the statement was not always balanced with the fact that to make these items more energy effective, it had to be built lighter, thus reducing the life expectancy, that often resulted in any energy savings being required to be used in ongoing capital investment. We have quietly moved from a 25-year life expectancy to a 10 to 15-year timeframe as being standard.

Manufacturers continually invest in new designs and technology that in my experience are sometimes rushed to market for the final stage of research and development by the user. Facility managers that are provided with the newest technology or equipment designs are often in an ongoing relationship with the supplier service team as they work the final bugs out of the installation.

Over time we have learned the importance of ice sheet air management that compliments the industrial refrigeration plant. We have also learned the importance of ensuring these two systems are integrated as having two separate suppliers and installers can create a challenge for facility staff as both companies blame the other for the operational issues. The latest operational change is the purchasing of exclusive or proprietary technology/software on equipment that does not allow the facility owner to seek competitive pricing for services over the life of the purchase. Often these decisions are made by individuals at the design stage who have no comprehension with the long-term impact on the full life expectancy of the investment. A used vehicle sales lot television commercial that stated “have you ever wondered who is paying for the huge sales building and related amenities” can in some cases be applied to our industry. Any innovation or technology research and development is always paid for by the purchaser.

These advancements have complicated the efforts of the ORFA to try and stay ahead of the educational needs and guidance to our members. There was a time we could focus beyond the theory of the cycle of refrigeration to include maintenance information that might result in operational costs savings. However, the continued advancement in refrigeration equipment has our training remain exclusively focused on “the science of the removal and transfer of heat” and how it impacts ice quality. The next generation of practitioners will require a variety of new tools in their operational and managerial toolbox. The ORFA will continue to remain proactive in the collection and sharing of information but can only be successful if our members continue to share their experiences.