With the objective of using less energy and reducing unnecessary waste , VMG Consultants is assisting Pick n Pay to refurbish its air conditioning systems across multiple stores with energy-efficient technology while keeping over 15 tonnes of waste from landfill .
PROJECT
INCORPORATING COLD CHAIN
Pick n Pay upcycles air-conditioning systems , saving energy and reducing waste
Compiled by Eamonn Ryan with technical input from Nigel Pengelly , managing member of VMG Consultants , and Frikkie Kleyns , technical manager at Elmec Airconditioning
With the objective of using less energy and reducing unnecessary waste , VMG Consultants is assisting Pick n Pay to refurbish its air conditioning systems across multiple stores with energy-efficient technology while keeping over 15 tonnes of waste from landfill .
For instance , during the 2020 renovation of Pick n Pay On Nicol , the retailer benefited from the significant environmental perk of refurbishing air handling units ( AHUs ) instead of replacing them . Nigel Pengelly , managing member of VMG Consultants says that to date , 14 stores have had their AHUs refurbished , with another 17 in the pipeline .
This includes refurbishing watercooled packaged units to air-cooled ones , focusing on the waste hierarchy of reducing and reusing to improve sustainability . Each refurbishment keeps about half a tonne of polystyrene - which isn ’ t recyclable – from landfill , sparking a wider rollout of the strategy .
“ Existing equipment , which is 20 years old but essentially relies on technology which is over 40 years old and therefore was designed and installed using energyinefficient technology – because there were no alternatives . Today , I ask landlords ‘ Would you drive a 45-year-old car , just because it still works ?’. By using new technology such as computer-aided design and sophisticated computer programs , today we can optimise a supermarket ’ s air-conditioning units and reduce the size and running costs of equipment required that are 30-60 % more efficient ,” says Pengelly . VMG has been working with Pick n Pay for 40 years , he says , and has built a strong trusted relationship .
In one refurbishment project , Pengelly notes that a like-for-like replacement would have cost Pick n Pay ’ s landlord around R13 million , compared to a refurbishment cost of R8.5 million for the air-conditioning . “ There are huge savings to be made if you do it right .”
Pengelly , who has been integral to the refurbishment project , highlights the significant advantages of working with LG ' s state-of-the-art controls . " LG , along with other major manufacturers , now offers comprehensive control solutions for their equipment . This ‘ one-stop-shop ’ approach simplifies relatively complex control logic and ensures seamless compatibility with their highly technical equipment ."
LG ’ s innovation extends beyond traditional air conditioning units . Its Smart 5 Controller , paired with an associated I / O ( input / output ) module , represents a leap forward in its control technology . This system provides complete control over all HVAC components , and not limited to LG ’ s own equipment . “ What sets LG apart is its high-quality ‘ built-in ’ control-programmes and ease of programming for the end-user . Unlike outsourcing alternative controls where software development might be
LG Condensing units .
tedious and fraught with time-consuming problems , LG ’ s controllers are supported by an inhouse team that produces tried and tested well-designed programs , which are constantly being improved and updated at no additional cost . This means you get advanced features without the need for extensive customised programming and expensive upgrades .”
The ease of on-site programming LG systems is another key benefit . The Smart 5 Controller ’ s interface is designed to be accessible even to those without a background in computer science . Pengelly praised the system for its intuitive design , which eliminates the need for expensive and complex custom software solutions .
This technological advancement aligns perfectly with Pick n Pay ’ s sustainability goals . By upgrading to these advanced LG systems , the retailer not only improves energy efficiency but also reduces operational costs and environmental impact .
Pengelly , who has been working with Pick n Pay for 35 years , comments on the retailer ’ s commitment to innovation and sustainability . “ Previously , Pick n Pay ’ s fresh air systems were set manually and locked in place based on the maximum possible population density . By implementing CO₂ sensors , we ’ ve introduced a dynamic , responsive system that adjusts fresh air supply based on the actual store occupancy throughout the day .”
One of the most impressive features of LG ’ s technology is its connectivity . The Smart 5 Controller can be monitored and adjusted remotely via a modem , allowing real-time control from anywhere in the world .
All images supplied by Elmec Airconditioning .
“ We can make adjustments from our office or even a smartphone , no matter where the store is located . This level of remote control and programmability is a game-changer for maintaining and optimising air conditioning systems efficiently .”
In addition to advanced controls , Pengelly has also recommended installation of other innovative equipment options , such as VRF chillers . These chillers , which use inverter technology to modulate performance rather than simple on / off cycling , offer increased efficiency and reliability . “ VRF chillers are a great example of how modern technology can enhance our systems . They provide
Air cooled package unit converted to hybrid package unit .
precise control and are much more efficient compared to traditional chillers .”
The integration of plug fans and other components from various suppliers , including HC Aircon and Ziehl Abegg , further complements the system ' s efficiency . By VMG sourcing these components in bulk , Pick n Pay benefits from cost savings while ensuring highquality performance . The company also obtained a 10-year warranty on compressors from many reputable manufacturers due to their high standards of maintenance .
“ The beauty of plug fans lies in their ability to provide exact air quantities with ease . Unlike traditional belt-driven centrifugal fans , which often require cumbersome adjustments to pulleys and belts , plug fans allow for straightforward tuning . This capability ensures that we can achieve the exact air flows we require and corresponding energy savings .”
Plug fans are particularly effective because their power consumption drops significantly as air flow is reduced . “ When we decrease the air flow by a small margin , the power consumption decreases significantly . This results in substantial energy savings , which is crucial for maintaining operational efficiency and reducing costs ,” Pengelly explains .
Additionally , the advent of computer programs and advanced design tools has transformed the approach to air conditioning system design and replacement . In the past , systems were designed manually with rudimentary tools , leading to inefficiencies .
22 www . coldlinkafrica . co . za COLD LINK AFRICA • November / December 2024