Industrial refrigerators are complex systems on which the safety of products in supermarkets, warehouses and production workshops depends. Unlike household models, they work with other types of refrigerants, are designed for high loads and require professional maintenance. The main question that worries owners and technicians: what do industrial refrigerators use?so that they effectively cool large volumes with minimal energy consumption?
The choice of refrigerant depends on many factors: type of equipment, temperature conditions, environmental standards and even the climatic conditions of the region. For example, one gas is suitable for freezers with a temperature of −30°C, but a completely different gas is suitable for cooling fruit at +2°C. In this article we will analyze all the current types of refrigerants, their advantages, disadvantages and nuances of use in industrial refrigeration units.
Let us immediately note: since 2020, the EU and Russia have strict restrictions on the use of freons with a high global warming potential (GWP), so many enterprises are switching to natural refrigerants - ammonia or CO₂. However, classic freons are still in demand in outdated equipment. Let's consider each option in detail.
1. Freons (hydrofluorocarbons, HFCs): classics with limitations
Freons are synthetic refrigerants based on fluorine, chlorine and carbon that have been used in refrigeration technology for decades. The most common brands for industrial systems: R-134a, R-404A, R-407C i R-410A. They are easy to use, compatible with most compressors and do not require special safety measures when refueling.
However, freons have two drawbacks: high global warming potential (GWP) and a gradual ban on use in new installations. For example, R-404A (GWP = 3922) is already excluded from EU standards, and R-134a (GWP = 1430) is only allowed for servicing existing equipment. This means that refilling industrial refrigerators with freons is becoming more and more expensive.
- ✅ Pros: high efficiency, low toxicity, compatibility with most systems
- ❌ Disadvantages: environmental restrictions, high cost due to shortages, the need for disposal according to strict rules
- 🔧 Where they are used: in old refrigerators, commercial equipment, air conditioning systems
⚠️ Attention: From 2026 in Russia it is planned to complete ban on the import of freons with GWP above 2500 for new installations. Check the current standards in Rosprirodnadzor before refueling.
2. Ammonia (R-717): powerful, but dangerous
Ammonia (R-717) is a natural refrigerant with zero GWP, which is actively returning to industry due to its environmental friendliness and high thermal conductivity. It surpasses freons in energy efficiency by 10–15%, which is critical for large refrigeration systems (for example, in meat processing plants or logistics hubs).
However, ammonia has 3rd hazard class according to GOST 12.1.007-76: it is toxic, explosive at a concentration in the air of 15% and requires special measures precautions. To use it you need:
- 🏭 Sealed systems with double circuits (in case of leakage)
- 🚨 Leak sensors and emergency ventilation
- 👷 Operating personnel with permission to work with AHOV (emergency chemically hazardous substances)
Despite the difficulties, ammonia remains the leader for large industrial facilities. For example, in warehouses "Magnit" and "Tapes" up to 60% of refrigeration systems operate on R-717.
| Parameter | Ammonia (R-717) | CO₂ (R-744) | Freon R-404A |
|---|---|---|---|
| GWP (warming potential) | 0 | 1 | 3922 |
| Toxicity | High (class 3) | Low (4th class) | Low |
| Energy efficiency | Very high | High (at low temperatures) | Average |
| Refilling cost (per 1 kg) | ~300–500 ₽ | ~150–250 ₽ | ~1200–1800 ₽ |
⚠️ Attention: If an ammonia leak exceeds 10 kg, it is necessary to urgently evacuate personnel and call the Ministry of Emergency Situations. Even small concentrations (0.02 mg/l) cause irritation of mucous membranes.
3. Carbon dioxide (CO₂, R-744): environmentally friendly, but capricious
CO₂ is the refrigerant of the future for industrial refrigerators. Its main advantages:
- 🌱 GWP = 1 (almost zero harm to the climate)
- 💰 Low cost (5-10 times cheaper than freons)
- 🔥 Non-flammable and non-toxic (hazard class 4)
However, There is CO₂ critical point at +31.1°C, which creates problems in hot climates. For normal operation of systems at R-744 requires:
- ❄️ Additional coolers (for example, subcoolers) to maintain pressure
- 🛠️ Compressors designed for high pressure (up to 100 bar)
- 📉 Special cascade or transcritical cycle schemes
CO₂ is ideal for low-temperature chambers (−20°C and below), but is not always suitable for medium temperature zones. Large networks, such as IKEA and Auchanare actively switching to R-744 in new projects, but modernizing old systems often requires serious investments.
4. Hydrochlorofluorocarbons (HCFCs): An aging alternative
HCFCs such as R-22were once popular in industry due to their low cost and good thermodynamic properties. However, since 2020, their production and import in Russia is prohibited due to damage to the ozone layer (Montreal Protocol). However, R-22 can still be found in older systems, where it is gradually being replaced by R-422D or R-438A (drop-in-substitutes).
The main problems of HCFCs:
- 🌍 Destroy the ozone layer (ODP > 0)
- 🚫 Prohibited for new installations
- 💸 The price for recycled R-22 has increased 3 times over the last 5 years
If your equipment is still running on R-22it is recommended to plan retrofit the transition to a modern refrigerant. This will require replacing the oil in the compressor, seals and, possibly, valves.
What is retrofit of a refrigeration system?
Retrofit is a set of works to adapt the old system to a new refrigerant. Includes: flushing the circuit, changing the oil (for example, from mineral to POE for HFCs), installing new filter driers and setting up the automation. The average cost of retrofitting an industrial chamber is from RUB 150,000.
5. Mixed refrigerants: a balance between efficiency and ecology
Industrial refrigerators often use mixtures of refrigerants that combine the advantages of different components. Popular options:
- R-407F —replacement R-404A with GWP = 1825 (50% lower)
- R-448A —alternative R-404A for low-temperature systems
- R-449A —optimized for operation at −40°C
Advantages of mixtures:
- 🔄 Possibility drop-in-replacement (without system upgrade)
- 📉 Reduced GWP compared to pure freons
- ⚙️ Compatibility with existing compressors (for example, Copeland or Bitzer)
However, mixtures also have disadvantages: they can divided into fractions in case of leaks, which requires a complete recharge of the system. In addition, their energy efficiency is 5-10% lower than that of ammonia or CO₂.
Check compatibility with the oil in the compressor|Replace the filter drier|Evacuate the system (depth of at least 0.5 mbar)|Adjust the expansion valves for the new refrigerant -->
6. How to choose a refrigerant for an industrial refrigerator?
The choice depends on five key factors:
- Temperature conditions:
- For
−40°C and below— ammonia or CO₂ in cascade systems - For
0…−10°C— freons (R-407F) or CO₂ in the subcritical cycle
- For
Calculation example for a meat processing plant:
- Chamber area: 500 m² (−25°C)
- Optimal refrigerant: ammonia (R-717) or CO₂/R-744 v cascade
- Energy savings: up to 20% compared to R-404A
- Payback of transition: 3–5 years
7. Refilling rules: what you need to know?
Refilling an industrial refrigerator is not only pumping gas, but also a set of measures for diagnosing and setting up the system:
- Diagnostics: checking for leaks (with a leak detector or nitrogen), monitoring the pressure in the system. circuit
- Evacuation: removal of moisture and air (vacuum of at least 0.5 mbar for 30 minutes)
- Refilling: metered addition of refrigerant taking into account passport standards (for example, for R-404A — 0.8–1.2 kg/kW of cooling capacity)
- Setting: adjusting expansion valves, checking overheating and subcooling
Critical errors that lead to breakdowns:
- ❌ Refilling without evacuation → moisture in the system → compressor corrosion
- ❌ Exceeding the refrigerant rate → water hammer and compressor failure
- ❌ Using incompatible oil → jamming of bearings
⚠️ Attention: When refueling ammonia systems, be sure to use special hoses with copper braids - ordinary rubber ones can be destroyed from contact with R-717.
FAQ: Frequently asked questions about refilling industrial refrigerators
Is it possible to refill an industrial refrigerator with household freon (for example, R-134a)?
No, this will lead to breakdown. Household freons have low cooling capacity and are not designed for use. for high loads. For example, R-134a is suitable for automobile air conditioners, but not for chambers with a temperature of −20°C. For industrial systems, use only specialized refrigerants: R-404A, R-717 or R-744.
How often do you need to refill the refrigerator?
Is the refrigerant normal? is not consumed - refilling is required only in case of leaks. Check frequency:
- Ammonia systems: once every 3 months (checking leakage sensors is required)
- CO₂ systems: once every 6 months (pressure check)
- Freon: once a year (if not signs of a leak)
Signs of a leak: drop in cooling capacity, freezing of pipelines, alarms.
What to do if two refrigerants are mixed in the system?
Mixing of refrigerants (for example, R-404A i R-22) leads to:
- Increased pressure in the circuit
- Deterioration of heat transfer
- Risk of chemical reactions (for example, formation of acids)
Solution: complete flushing the system with nitrogen, replacement of oil and filters, refilling with clean refrigerant. It is impossible to fix this on your own - you need to call a specialist.
How much does it cost to refill an industrial refrigerator?
The cost depends on the type refrigerant and system volume:
| Refrigerant | Price per 1 kg (₽) | Average cost of refilling (from) |
|---|---|---|
| R-404A | 1500–1800 | 50 000 |
| R-717 (ammonia) | 300–500 | 30,000 (but expensive installation) |
| R-744 (CO₂) | 150–250 | 40,000 (special equipment required) |
The price includes: refrigerant, technician work, diagnostics and setup For cascade systems (for example, CO₂/ammonia), the cost can reach 200,000. ₽.
Is it possible to refuel the refrigerator yourself?
For industrial systems self-refueling is prohibited for several reasons:
- ⚠️ Risk of leakage of toxic substances (ammonia) or explosion
- ⚠️ The need for certified equipment (vacuum pumps, collectors)
- ⚠️ Rostechnadzor requirements for work with hazardous chemicals (for ammonia)
Exception - refilling freon systems with a small volume (up to 1 kg) with approval. But even in this case, the following is required:
- Leak detector (electronic or ultrasonic)
- Gauge manifold with valves
- Protective gloves and glasses