FGN specialises in natural refrigerants with a core focus on CO2, so was wellsuited to undertake this complex project. " This integrated plant, incorporating air conditioning, represents a significant and novel project for FGN as well," said Arnold.

Massmart identified East London as a region with significant growth potential, warranting the development of a new store – their first in this location. This project represents a collaborative effort between Massmart, who leases the property, and the property developer M & F Giuricich Developments. Massmart ' s decision to establish a presence in East London aligns with their broader strategy to expand their footprint across South Africa. This new, sustainably cooled store reflects Massmart ' s growth strategy and commitment to embracing innovative and environmentally conscious solutions.

" The facility incorporates an integrated refrigeration and air conditioning system, wherein a single plant supplies CO2 refrigerant to both refrigeration and air handling units( AHUs)," Arnold stated. This design represents a significant departure from the conventional Massmart configuration, which typically employs discrete refrigeration and chilled water air conditioning systems. " Historically, standard Makro installations utilised independent refrigeration and chilled water-based air conditioning systems. However, this facility features a unified system where the chilled water AHUs have been replaced with direct expansion( DX) AHUs. The CO2 refrigerant for these DX units is supplied directly from the central refrigeration plant, representing a notably unique approach."

Arnold highlighted the innovative nature of implementing such an integrated system on this magnitude. " Based on my knowledge, there is no comparable system currently operational in South Africa. It is highly likely that this represents

Refrigeration rack B within plant room.

a pioneering application at this scale and complexity. The store itself is a smaller Makro format, not the expansive footprint typically observed. Consequently, both the refrigeration and air-conditioning capacities are somewhat lower than those of a standard store. However, the integration of these systems remains a unique and commendable aspect of this project." The project was executed within an impressively short timeframe, with construction commencing in April 2024 and the store ' s opening occurring just weeks before this discussion. " This rapid completion timeline is notable, particularly for a new, green-built project." Dewing Construction served as the principal contractor, with Engineering Solutions overseeing the refrigeration components and AirFire Solutions managing the air conditioning installation.

Despite the unified nature of the central plant, distinct contractors were responsible for the refrigeration and air conditioning systems, with the interface occurring at the AHUs. " The refrigeration contractor was

responsible for the installation of refrigerant piping up to the AHUs, while the HVAC contractor supplied and installed the AHUs along with the associated ductwork and distribution elements." The air conditioning system provides climate control for the entirety of the facility, encompassing the retail area, liquor store and administrative offices. The refrigeration plant serves critical temperature-controlled zones, including the main freezer room, main cold room, perishable goods receiving area, and a range of refrigerated display cases located on the sales floor.

The primary drivers for this innovative system integration were a specific directive from Massmart mandating the use of CO2 as the refrigerant and a parallel objective to enhance overall energy efficiency. " This project specification was further augmented to include the air conditioning system within this unified plant. Traditionally, air conditioning was provided by a separate chilled water system. However, the specification for this project was modified to utilise a DX CO2 system

supplied by the integrated refrigeration plant." The successful implementation of a pilot project in Woodmead, Gauteng, which integrated the liquor store ' s air handling unit with the CO2 refrigeration system, served as a precedent and proof of concept for this comprehensive integration in the East London store.

The advantages of this pioneering integrated system are both environmental and economic. " This approach yields

The facility incorporates an integrated refrigeration and air conditioning system, wherein a single plant supplies

CO2 refrigerant to both refrigeration and air handling units( AHUs).

All images supplied by Future Green Now