3-i

CHAPTER 3. MARKET AND TECHNOLOGY ASSESSMENT 

TABLE OF CONTENTS 

3.1 INTRODUCTION ........................................................................................................... 3-1 

3.1.1 Definitions............................................................................................................ 3-1 

3.2 MARKET ASSESSMENT .............................................................................................. 3-4 

3.2.1 Trade Association ................................................................................................ 3-4 

3.2.2 Manufacturers and Market Share......................................................................... 3-4 

3.2.2.1 Small Businesses...................................................................................... 3-7 

3.2.3 Regulatory Programs ........................................................................................... 3-8 

3.2.3.1 California ................................................................................................. 3-8 

3.2.3.2 Canada...................................................................................................... 3-9 

3.2.3.3 Canadian Standards Association............................................................ 3-10 

3.2.3.4 Australia................................................................................................. 3-11 

3.2.4 Non-Regulatory Initiatives................................................................................. 3-11 

3.2.4.1 ENERGY STAR .................................................................................... 3-12 

3.2.4.2 Consortium for Energy Efficiency......................................................... 3-12 

3.2.4.3 Federal Energy Management Program .................................................. 3-12 

3.2.4.4 Rebate Programs .................................................................................... 3-12 

3.2.5 Equipment Classes............................................................................................. 3-13 

3.2.6 Shipments........................................................................................................... 3-19 

3.2.6.1 Appliance Magazine Data...................................................................... 3-21 

3.2.6.2 Current Industrial Reports...................................................................... 3-21 

3.2.7 Equipment Lifetimes.......................................................................................... 3-24 

3.2.8 Market Performance Data.................................................................................. 3-25 

3.3 TECHNOLOGY ASSESSMENT.................................................................................. 3-28 

3.3.1 Technologies and Designs Relevant to All Equipment Classes ........................ 3-28 

3.3.1.1 Higher Efficiency Lighting.................................................................... 3-28 

3.3.1.2 Higher Efficiency Lighting Ballasts ...................................................... 3-29 

3.3.1.3 Remote Lighting Ballast Location......................................................... 3-29 

3.3.1.4 Higher Efficiency Expansion Valves..................................................... 3-29 

3.3.1.5 Higher Efficiency Evaporator Fan Motors ............................................ 3-30 

3.3.1.6 Evaporator Fan Motor Controllers......................................................... 3-31 

3.3.1.7 Higher Efficiency Evaporator Fan Blades ............................................. 3-31 

3.3.1.8 Increased Evaporator Surface Area ....................................................... 3-32 

3.3.1.9 Low-Pressure Differential Evaporators ................................................. 3-32 

3.3.1.10 Anti-Sweat Heater Controllers............................................................. 3-33 

3.3.1.11 Improved or Thicker Insulation ........................................................... 3-33 

3.3.1.12 Defrost Mechanism.............................................................................. 3-33 

3.3.1.13 Defrost Cycle Control.......................................................................... 3-34 

3.3.1.14 Thermoacoustic Refrigeration ............................................................. 3-34 

3.3.1.15 Magnetic Refrigeration ........................................................................ 3-35 

3.3.1.16 Electro-Hydrodynamic Enhanced Heat Transfer................................. 3-35 

3.3.1.17 Copper Rotor Motors ........................................................................... 3-36 

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3.3.2 Designs Relevant Only to Equipment without Doors........................................ 3-36 

3.3.2.1 Air-Curtain Design................................................................................. 3-36 

3.3.3 Technologies and Designs Relevant Only to Self-Contained Equipment ......... 3-36 

3.3.3.1 Higher Efficiency Compressors............................................................. 3-36 

3.3.3.2 Liquid Suction Heat Exchangers ........................................................... 3-37 

3.3.3.3 Increased Condenser Surface Area ........................................................ 3-37 

3.3.3.4 Higher Efficiency Condenser Fan Motors ............................................. 3-38 

3.3.3.5 Condenser Fan Motor Controllers ......................................................... 3-38 

3.3.3.6 Higher Efficiency Condenser Fan Blades.............................................. 3-38 

REFERENCES .......................................................................................................................... 3-40 

LIST OF TABLES 

Table 3.2.1 California Energy Commission Efficiency Regulations for Commercial Ice-Cream 

Freezers.................................................................................................................. 3-9 

Table 3.2.2 Canadian Efficiency Regulations for Commercial Ice-Cream Freezers.............. 3-10 

Table 3.2.3 Canadian Standards Association Equipment Classes and Efficiency Ratings .... 3-11 

Table 3.2.4 Commercial Refrigeration Equipment Families.................................................. 3-16 

Table 3.2.5 Commercial Refrigeration Equipment Classes.................................................... 3-18 

Table 3.2.6 Air-Conditioning and Refrigeration Institute Shipments of Commercial 

Refrigerators and Freezers by Equipment Class.................................................. 3-20 

Table 3.2.7 Historical Shipments of Refrigerated Display Cases........................................... 3-21 

Table 3.2.8 Statistical Forecasts of Refrigerated Display-Case Shipments............................ 3-21 

Table 3.2.9 Shipments of Open Refrigerated Display Cases (Remote Condensing and SelfContained)............................................................................................................ 3-22 

Table 3.2.10 Shipments of Closed Refrigerated Display Cases (Remote Condensing and SelfContained)............................................................................................................ 3-23 

Table 3.2.11 Shipments of Commercial Reach-In Cabinets (Remote Condensing and SelfContained)............................................................................................................ 3-24 

Table 3.2.12 Estimates for Commercial Refrigeration Equipment Lifetimes .......................... 3-25 

LIST OF FIGURES 

Figure 3.2.1 Domestic Refrigerated Display Case Market Shares ............................................. 3-6 

Figure 3.2.2 Market Performance Data for the VOP.RC.M Equipment Class......................... 3-26 

Figure 3.2.3 Market Performance Data for the SVO.RC.M Equipment Class......................... 3-26 

Figure 3.2.4 Market Performance Data for the HZO.RC.M Equipment Class......................... 3-27 

Figure 3.2.5 Market Performance Data for the VCT.RC.L Equipment Class.......................... 3-27 

Figure 3.2.6 Market Performance Data for the VOP.RC.M, SVO.RC.M, and HZO.RC.M 

Equipment Classes: Comparison of Air-Curtain Angles .................................... 3-28 

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 EE-2006-STD-0126 COMMENT 23.2
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CHAPTER 3. MARKET AND TECHNOLOGY ASSESSMENT 

3.1 INTRODUCTION 

This document details the market and technology assessment that the U.S. Department of 

Energy (DOE) has conducted in support of the ongoing energy conservation standards 

rulemakings for commercial refrigeration equipment (CRE), including commercial ice-cream 

freezers; self-contained commercial refrigerators, commercial freezers, and commercial 

refrigerator-freezers without doors; and remote condensing commercial refrigerators, 

commercial freezers, and commercial refrigerator-freezers. These rulemakings are mandated by 

the Energy Policy Act of 2005 (EPACT 2005), and are effective for equipment manufactured on 

or after January 1, 2012. 

This chapter consists of a market and technology assessment. The goal of the market 

assessment is to develop a qualitative and quantitative characterization of the CRE industry and 

market structure based on publicly available information and information submitted by 

manufacturers and other stakeholders. Manufacturer characteristics and market shares, existing 

regulatory and non-regulatory efficiency improvement initiatives, equipment classes, and trends 

in markets and equipment characteristics are addressed. The goal of the technology assessment 

is to develop a preliminary list of technologies that could improve the efficiency of commercial 

refrigeration equipment. 

Commercial refrigeration equipment is used primarily to store and display perishable 

food products for sale in food-sales buildings (e.g., supermarkets and convenience stores), some 

multi-line retail stores, and in some food service applications like restaurants, salad bars, and 

cafeterias. The vast majority of equipment covered under this rulemaking, however, is used in 

food-sales buildings, which represent about 1.75 percent (1.26 billion square feet) of the 

commercial floor space in the United States and 4.87 percent (668 trillion British thermal units 

per year (Btu/yr)) of the total energy consumption attributed to the commercial sector.a Fully 

5.84 percent (61 terawatt hours per year (TWh/yr)) of the electrical consumption in commercial 

buildings is attributed to food-sales buildings.1 Their high energy-use intensity is largely due to 

the extensive use of commercial refrigeration equipment.

3.1.1 Definitions 

Section 136(c) of EPACT 2005 amended section 342 of the Energy Policy Conservation 

Act (EPCA or the Act) to include new subsection (c)(4)(A) (42 U.S.C. 6313(c)(4)(A)), which 

mandates that DOE issue energy conservation standards by rule no later than January 1, 2009, 

for the following equipment manufactured on or after January 1, 2012: commercial ice-cream 

freezers; self-contained commercial refrigerators, commercial freezers, and commercial 

refrigerator-freezers without doors; and remote condensing commercial refrigerators, 

commercial freezers, and commercial refrigerator-freezers. 

 

a

 The values indicated are source energy values. 

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3-2

Section 136(a)(3) of EPACT 2005 amended section 340 of EPCA, in part by adding 

subsection 340(9) (42 U.S.C 6311(9)) with definitions for the following terms that describe 

commercial refrigeration equipment: 

 “(9)(A) The term ‘commercial refrigerator, freezer, and refrigerator-freezer’ means 

refrigeration equipment that— 

 (i) is not a consumer product (as defined in section 321); 

 (ii) is not designed and marketed exclusively for medical, scientific, or research 

purposes; 

 (iii) operates at a chilled, frozen, combination chilled and frozen, or variable 

temperature; 

 (iv) displays or stores merchandise and other perishable materials horizontally, 

semivertically, or vertically; 

 (v) has transparent or solid doors, sliding or hinged doors, a combination of 

hinged, sliding, transparent, or solid doors, or no doors; 

 (vi) is designed for pull-down temperature applications or holding temperature 

applications; and 

 (vii) is connected to a self-contained condensing unit or to a remote condensing 

unit.

 

(B) The term ‘holding temperature application’ means a use of commercial 

refrigeration equipment other than a pull-down temperature application, except a 

blast chiller or freezer. 

 * * * 

 (D) The term ‘pull-down temperature application’ means a commercial 

refrigerator with doors that, when fully loaded with 12 ounce beverage cans at 90 

degrees F, can cool those beverages to an average stable temperature of 38 degrees 

F in 12 hours or less. 

 (E) The term ‘remote condensing unit’ means a factory-made assembly of 

refrigerating components designed to compress and liquefy a specific refrigerant 

that is remotely located from the refrigerated equipment and consists of one or 

more refrigerant compressors, refrigerant condensers, condenser fans and motors, 

and factory supplied accessories. 

 (F) The term ‘self-contained condensing unit’ means a factory-made assembly of 

refrigerating components designed to compress and liquefy a specific refrigerant 

that is an integral part of the refrigerated equipment and consists of one or more 

refrigerant compressors, refrigerant condensers, condenser fans and motors, and 

factory supplied accessories.” 

EPACT 2005 did not explicitly define the terms “self-contained commercial refrigerator, 

freezer, or refrigerator-freezer” or “remote condensing commercial refrigerator, freezer, or 

refrigerator-freezer.” DOE interpreted these two terms to mean “commercial refrigerator, 

freezer, or refrigerator-freezer that is connected to a self-contained condensing unit” and 

“commercial refrigerator, freezer, or refrigerator-freezer that is connected to a remote 

condensing unit,” respectively. 

Accordingly, the three categories of equipment covered under this rulemaking are: 

 EE-2006-STD-0126 COMMENT 23.2
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1. Remote condensing commercial refrigerators, commercial freezers, and commercial 

refrigerator-freezers: Under EPCA, this equipment includes commercial refrigerators, 

commercial freezers, and commercial refrigerator-freezers that have a remote condensing 

unit, except for any remote condensing equipment that would meet DOE’s definition of 

“ice-cream freezer” as set forth at 10 CFR 431.62, 71 FR 71369. They are typically used 

to store and display products for direct sale to the consumer, and are referred to as 

“refrigerated display cases,” “display cabinets,” or “merchandisers.” The remote 

condensing unit has at least one compressor and a condenser coil, and most are connected 

to a remote condensing unit that consists of multiple compressors (a compressor “rack”) 

that serves multiple display cases. 

2. Self-contained commercial refrigerators, commercial freezers, and commercial 

refrigerator-freezers without doors: Under EPCA, this equipment includes all types of 

commercial refrigerators, commercial freezers, and commercial refrigerator-freezers that 

have a self-contained condensing unit and have no doors, except for self-contained 

commercial equipment that meets DOE’s definition of “ice-cream freezer” as set forth at 

10 CFR 431.62, 71 FR 71369. As with remote condensing equipment, this equipment is 

typically used to store and display products for direct sale to the consumer, and is 

commonly referred to as “refrigerated display cases,” “display cabinets,” or 

“merchandisers.” Self-contained equipment is defined as having an integral condensing 

unit (i.e., the condensing unit is not remote from the refrigerated cabinet). (See 42 U.S.C. 

6311(9)(F), added by EPACT 2005, section 136(a)(3).) The 2006 American Society of 

Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE) Refrigeration 

Handbook (Chapter 47, p. 47.1) defines “reach-in” refrigerators or freezers as being 

upright and box shaped, and having hinged or sliding doors. Given this definition, selfcontained reach-in commercial refrigerators, commercial freezers, and commercial 

refrigerator-freezers (i.e., self-contained equipment with doors) are not covered in this 

rulemaking, which only covers self-contained equipment without doors. 

3. Commercial ice-cream freezers: The EPCA provision that required this rulemaking 

identifies “ice-cream freezers” separately from “self-contained commercial refrigerators, 

freezers, and refrigerator-freezers without doors” and “remote condensing commercial 

refrigerators, freezers, and refrigerator-freezers.” (42 U.S.C. 6313(c)(4)(A), added by 

EPACT 2005, section 136(c)) The Act neither specifies nor indicates that “ice-cream 

freezers” are limited to equipment with a particular door configuration (e.g., with or 

without doors) or type of condensing unit (i.e., remote or self-contained). Thus, pursuant 

to EPCA’s definition of “commercial refrigerator, freezer, and refrigerator-freezer” (42 

U.S.C. 6311(9)(A), added by EPACT 2005, section 136(a)(3)), DOE believes 

commercial ice-cream freezers include equipment with all door types (i.e., solid doors, 

transparent doors, or no doors) and configurations (e.g., vertical or horizontal), as well as 

equipment with either integral or remote condensing units (i.e., self-contained or remote 

condensing). 

On December 8, 2006, DOE published a final rule, in which it adopted test procedures for 

commercial refrigeration equipment. In this final rule, DOE adopted the following definition for 

“ice-cream freezer:” “a commercial freezer that is designed to operate at or below -5°F [degrees 

Fahrenheit] (-21°C [degrees Celsius]) and that the manufacturer designs, markets, or intends for 

 EE-2006-STD-0126 COMMENT 23.2
3-4

the storing, displaying, or dispensing of ice cream.” 10 CFR 431.62, 71 FR 71369. In addition, 

this final rule prescribed the rating temperature at -15°F for ice-cream freezers. 10 CFR 431.64, 

71 FR 71370. 

3.2 MARKET ASSESSMENT 

The following market assessment identifies the manufacturer trade association, domestic 

manufacturers of commercial refrigeration equipment, manufacturer market share, regulatory 

programs, and non-regulatory initiatives; defines equipment classes; provides historical shipment 

data, shipment projections, and equipment lifetime estimates; and summarizes market 

performance data. 

3.2.1 Trade Association 

The Air-Conditioning and Refrigeration Institute (ARI) is the trade association of 

commercial refrigeration equipment manufacturers. On January 12, 2005, ARI developed an 

agreement with manufacturers to establish the commercial refrigerator manufacturers division 

(CRMD) within ARI, and develop and implement a certification program for commercial 

refrigerators, commercial freezers, and commercial refrigerator-freezers.

 The CRMD was originally a separate trade organization founded in 1933. It serves 

supermarkets, food stores, convenience stores, restaurants, hotels, motels, food processing 

establishments, and hospitals. The technical activities of CRMD include 

• harmonization of international equipment standards; 

• development of industry performance standards for commercial refrigeration equipment; 

• updating of industry guidelines for retail store fixture installation, design, energy 

conservation, electronic case controls, and specifications for equipment installation; 

• communicating with refrigerant suppliers and government agencies about 

environmentally acceptable chlorofluorocarbon (CFC) alternatives; and 

• providing input to government agencies concerning regulations affecting the industry. 

3.2.2 Manufacturers and Market Share 

Current ARI CRMD members are listed below; parent companies are shown in 

parentheses if applicable. 

 EE-2006-STD-0126 COMMENT 23.2
3-5

• Barker Company • Hussmann (Ingersoll 

Rand) • Spartan Showcase 

• Beverage-Air • Killion Industries • Structural Concepts 

Corp. 

• Columbus Showcase 

Co. • Kysor/Warren (Enodis) 

• Tyler Refrigeration 

(Carrier, United 

Technologies Corp.) 

• Continental 

Refrigerator 

• Master-Bilt Products 

(Standex) • Zero Zone 

• Federal Industries 

(Standex) • McCall Refrigeration 

• Hill Phoenix (Dover 

Corp.) • Southern Store Fixtures 

Source: CRMD manufacturers listed as of November 2006, 

http://www.ari.org/sections/section_groups/CommercialRefrigerator/manufacturers.htm. 

Non-ARI member CRE manufacturers are listed below; parent companies are shown in 

parentheses if applicable. 

• Amteko* • Howard/McCray • Silver King* 

• Arctic Air • Kelvinator • True Manufacturing* 

• Arctic Star* • McCray* • Turbo Air 

• Arneg USA* • Refcon* • Vogel* 

• Custom Deli* • Regan-Pinnacle 

• Custom Fabricators* • Royal Store Fixtures 

(Parisi)* 

*Based on ARI comment submitted to the Framework Document (ARI, No. 7 Exhibit A at p. 1)b with the addition of 

Silver King.2

Five major manufacturers hold the majority of the domestic market share of selfcontained and remote condensing commercial refrigeration equipment without doors; parent 

companies are listed in parentheses if applicable:3

• Hill Phoenix (Dover Corporation) 

• Hussmann Corporation (Ingersoll Rand) 

• Kysor/Warren (Enodis) 

• Tyler Refrigeration (Carrier, United Technologies Corporation) 

• Zero Zone 

Only self-contained refrigeration equipment without doors and remote condensing 

equipment are applicable under this rulemaking. True Manufacturing also manufactures self-

 

b

 A notation in the form “ARI, No. 7 Exhibit A at p. 1” identifies a written comment DOE has received and included 

in the docket of this rulemaking. This particular notation refers to a comment (1) by the Air-Conditioning and 

Refrigeration Institute (ARI), (2) in document number 7 Exhibit A in the docket of this rulemaking (maintained in 

the Resource Room of the Building Technologies Program), and (3) appearing on page 1 of document number 7 

Exhibit A. 

 EE-2006-STD-0126 COMMENT 23.2
3-6

contained commercial equipment and has a large share of shipments of self-contained 

commercial equipment without doors and commercial ice-cream freezers. 

According to Appliance Magazine, four companies represent approximately 85 percent of 

the U.S. refrigerated display case market, with approximately 185,000 units shipped in 2004.4 

However, Appliance Magazine provides no precise definition of a refrigerated display case and it 

is therefore unclear what specific types of equipment the data covers—equipment that is selfcontained versus remote condensing, and equipment with doors versus without doors. 

As of 2004, Hussmann Corporation, a division of Ingersoll Rand, was the largest 

domestic manufacturer of refrigerated display cases, holding approximately 48 percent of the 

U.S. market. Other manufacturers make up the remaining 52 percent of U.S. market share 

(Figure 3.2.1). 

Tyler Refrigeration

16%

Hill Phoenix

15%

Kysor/Warren

6%

Other

15%

Hussmann

48%

Source: Appliance Magazine, “28th Annual Portrait of the U.S. Appliance Industry,” September 2005. 

Figure 3.2.1 Domestic Refrigerated Display Case Market Shares 

Manufacturers in the “Other” category are listed below; parent companies are listed in 

parenthesis if applicable. 

 EE-2006-STD-0126 COMMENT 23.2
3-7

• Arneg USA • Killion Industries • True 

Manufacturing 

• Barker Company • Master-Bilt Products 

(Standex) • Turbo Air 

• Columbus Showcase 

Co. • Royal Store Fixture (Parisi) • Zero Zone 

• Federal Industries 

(Standex) • Southern Store Fixtures 

• Howard/McCray • Structural Concepts Corp. 

Source: Appliance Magazine, “28th Annual Portrait of the U.S. Appliance Industry,” September 2005. 

Manufacturers of commercial ice-cream freezers are listed below; parent companies are 

listed in parentheses if applicable. 

• Arctic Air • Hussmann (Ingersoll 

Rand)* 

• Structural Concepts 

Corp.* 

• Beverage-Air* • Kelvinator • True Manufacturing 

• Columbus Showcase 

Co.* • Kysor/Warren (Enodis)* 

• Tyler Refrigeration 

(Carrier, United 

Technologies Corp.)* 

• Continental 

Refrigerator* 

• Master-Bilt Products 

(Standex)* • Zero Zone* 

• Delfield (Enodis) • McCall Refrigeration* 

• Hill Phoenix (Dover 

Corp.)* • Silver King 

* Based on ARI comments submitted to the Framework Document (ARI, No. 7 Exhibit A at p. 1). 

3.2.2.1 Small Businesses 

DOE is considering the possibility that energy conservation standards for commercial 

refrigeration equipment would adversely affect small businesses. The Small Business 

Administration (SBA) defines small business manufacturing enterprises for commercial 

refrigeration equipment as those having 750 employees or fewer.5 SBA lists small business size 

standards for industries as they are described in the North American Industry Classification 

System (NAICS). The size standard for an industry is the largest that a for-profit concern can be 

in that industry and still qualify as a small business for Federal Government programs. These 

size standards are generally expressed in terms of the average annual receipts or the average 

employment of a firm. For commercial refrigeration equipment, the size standard is matched to 

NAICS code 333415, Air-Conditioning and Warm Air Heating Equipment and Commercial and 

Industrial Refrigeration Equipment Manufacturing, and is 750 employees. 

DOE studied the potential impacts on these small businesses in detail during the 

manufacturer impact analysis, which was conducted as a part of the notice of proposed 

rulemaking analysis. DOE identified nine small business commercial refrigeration equipment 

manufacturers which are listed below; parent companies are listed in parentheses if applicable. 

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• Barker Company • Southern Store Fixtures 

• Columbus Showcase Co. • Structural Concepts Corp. 

• Killion Industries • Turbo Air 

• Royal Store Fixture (Parisi) • Zero Zone 

• Regal-Pinnacle 

3.2.3 Regulatory Programs 

Both Canada and California have efficiency standards for commercial ice-cream freezers 

but not for remote condensing commercial equipment and self-contained commercial equipment 

without doors. In the case of remote condensing equipment, the Canadian Standards Association 

(CSA) established efficiency standards as part of its overall test standards. Australia has several 

efficiency standards for all the equipment covered in this rulemaking. 

The following States have established appliance efficiency regulations: Arizona, 

California, Connecticut, Maryland, Massachusetts, Minnesota, New Jersey, New York, Oregon, 

Rhode Island, Vermont, and Washington. Of these, California is the only State that explicitly 

regulates commercial ice cream freezers and remote condensing equipment with transparent 

doors. 

Minnesota and Vermont do not regulate commercial refrigeration equipment at all. 

Arizona, Oregon, Rhode Island, and Washington regulate certain types of commercial 

refrigeration equipment. However, these States specifically exclude commercial ice-cream 

freezers, remote condensing commercial equipment, and self-contained commercial equipment 

without doors. 

Connecticut, Maryland, Massachusetts, New Jersey, and New York regulate certain 

commercial refrigeration equipment, but do not mention commercial ice-cream freezers. 

Connecticut and Maryland do not mention remote condensing commercial equipment or selfcontained commercial equipment without doors. New York and Maryland legislation does not 

include remote condensing commercial equipment and self-contained commercial equipment 

without doors. New Jersey does not mention remote condensing commercial equipment, but 

does include self-contained commercial equipment without doors. However, New Jersey does 

not have any standards in place for self-contained commercial equipment without doors. 

3.2.3.1 California 

 California Energy Commission (CEC) Appliance Efficiency Regulations (effective July 

1, 2006) establish efficiency standards for commercial ice-cream freezers, but not for the other 

types of equipment covered in this rulemaking. The maximum allowed daily energy 

consumption (kilowatt hours (kWh) per day) for commercial ice-cream freezers varies based on 

the door type (i.e., solid or transparent) and volume (V). Table 3.2.1 shows the two different 

standard levels with two different effective dates of January 1, 2006 and January 1, 2007. 

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Table 3.2.1 California Energy Commission Efficiency Regulations for Commercial IceCream Freezers 

Equipment Type Type of 

Door 

Maximum Daily Energy 

Consumption [kWh] 

Effective January 1, 2006 

Maximum Daily Energy 

Consumption [kWh] 

Effective January 1, 2007 

Reach-in cabinets, pass-through Solid 0.398 x V + 2.28 0.39 x V + 0.82 

cabinets, and roll-in or rollthrough cabinets that are icecream freezers 

Transparent 0.940 x V + 5.10 0.88 x V + 0.33 

V = Volume in cubic feet (ft3) 

Source: Appliance Efficiency Regulations, July 2006, CEC-400-2006-002-REV1, section 1605.3, Table A-7. 

The CEC regulations also have a design requirement for lighting in remote condensing 

commercial equipment with transparent doors, remote condensing commercial equipment 

without doors, and self-contained commercial equipment without doors. This design 

requirement mandates that the internal illumination must be provided by T8 fluorescent lamps 

with electronic ballasts or a lighting system that has no fewer lumens per watt than a system 

using only T8 fluorescent lamps with electronic ballasts.6 This requirement is valid for all 

equipment manufactured and/or sold in California.

The test methods used for determining compliance with the CEC regulations are the 

American National Standards Institute/Association of Home Appliance Manufacturers 

(ANSI/AHAM) HRF-1-1979, Household Refrigerators, Combination Refrigerator-Freezers, and 

Household Freezers, for volume measurements; ANSI/ASHRAE Standard 117-1992, Method of 

Testing Closed Refrigerators, for energy consumption measurements of self-contained 

commercial refrigerators, commercial freezers and commercial refrigerator-freezers with doors; 

and ANSI/ASHRAE Standard 72-1998, Method of Testing Open Refrigerators, for energy 

consumption measurements of self-contained commercial refrigerators, commercial freezers, and 

commercial refrigerator-freezers without doors. The energy consumption tests are conducted 

with the following integrated average product temperatures (IAT):c

• Refrigerator compartment: 38°F ± 2°F (3.3°C ± 1.1oC) 

• Freezer compartment: 0°F ± 2°F (-17.8°C ± 1.1oC) 

• Wine chiller: 45°F ± 2°F (7.2°C ± 1.1oC) 

• Ice-cream cabinet: -5°F ± 2°F (-20.6°C ± 1.1oC) 

3.2.3.2 Canada 

The Natural Resources Canada (NRCan) Office of Energy Efficiency has energyefficiency standards for self-contained commercial “reach-in” refrigerators, freezers, and 

refrigerator-freezers with solid/opaque doors or transparent doors. Canada’s standards are based 

on California’s regulations.7 Because NRCan considers commercial ice-cream freezers a type of 

self-contained commercial reach-in freezer, these regulations apply to commercial ice-cream 

freezers. 

 

c

 Because the CEC standards for refrigerators and freezers are only for equipment with doors and a self-contained 

condensing unit, only the IAT for commercial ice-cream freezers is germane to this rulemaking. 

 EE-2006-STD-0126 COMMENT 23.2
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Canada’s approach differs from California’s. Rather than specifying the type of 

equipment covered, the Canadian standards define commercial refrigerators, commercial 

freezers, and commercial refrigerator-freezers by identifying only those units that are not

covered by standards. Manufacturers of commercial refrigerators and commercial freezers 

without doors are required to report the rated energy use of the equipment, although the 

equipment does not have to meet any standard at this time. The test method for determining 

compliance is ANSI/ASHRAE Standard 117-1992, Method of Testing Closed Refrigerators,

with the following specifications for the IAT: 

• Refrigerator compartment: 38°F ± 2°F (3.3oC ± 1.1oC) 

• Freezer compartment: 0°F ± 2°F (-17.8oC ± 1.1oC) 

• Wine chiller: 45°F ± 2°F (7.2oC ± 1.1oC) 

• Ice-cream cabinet: -5°F ± 2°F (-20.6oC ± 1.1oC) 

The two tiers of performance standards for self-contained commercial freezers (under 

which ice-cream freezers are classified) took effect April 1, 2007 and January 1, 2008, 

respectively. As Table 3.2.2 shows, maximum daily energy consumption depends on door type 

and volume. 

Table 3.2.2 Canadian Efficiency Regulations for Commercial Ice-Cream Freezers 

Equipment 

Type 

Type of Door 

Volume 

(V) 

(liters) 

Maximum Daily Energy 

Consumption (E) 

Effective April 1, 2007 

(kWh) 

Maximum Daily Energy 

Consumption (E) 

Effective January 1, 2008 

(kWh) 

Opaque < 340 E = 7.62 E = 7.07 

Opaque ≥ 340 E = 0.0141 x V + 2.83 E = 0.0141 x V + 2.28 

Self-contained 

commercial 

freezers Transparent - E = 0.0332 x V + 5.10 - 

Source: Amendment 9 to the Energy Efficiency Regulations published in Canada Gazette Part II, November 15, 2006. 

3.2.3.3 Canadian Standards Association 

CSA is an independent standards-setting agency that establishes test procedures and 

efficiency standards that the Canadian government typically adopts. The Canadian standard 

CAN/CSA C657-04, Energy Performance Standard for Refrigerated Display Cabinets 

(Merchandisers), applies to remote condensing commercial equipment with and without doors, 

and self-contained commercial equipment with and without doors, except as covered by CSA 

C827-98 (R2003). Commercial refrigerators and commercial freezers with doors (including 

commercial ice-cream freezers) are covered in a separate test procedure and standard, CSA 

C827-98 (R2003), Energy Performance Standard for Food Service Refrigerators and Freezers. 

This standard is a revision of the original CSA standard published in 1995. Among the changes 

are redefined equipment categories and new minimum energy performance standards (MEPS).d 

The CSA C657-04 standard divides commercial refrigeration equipment into seven 

classes and several sub-classes. Table 3.2.3 summarizes classes and MEPS levels from CSA 

 

d

 Changes to the standard make it extremely difficult to compare levels between the 1995 and updated standards. 

 EE-2006-STD-0126 COMMENT 23.2
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C657-04. For equipment with a remote condensing unit, the MEPS use a pre-determined remote 

condensing unit efficiency to calculate daily energy use. 

Table 3.2.3 Canadian Standards Association Equipment Classes and Efficiency Ratings8

Class IAT* 

(°F) Temperature Open/Closed Deck

Number of 

Air 

Curtains

Angle of Air 

Curtain 

from 

Vertical

MEPS 

2004 

(kWh/ft 

per day)

1 41.0 Medium Open Single/Multi 1 0-30° 4.0 

2 41.0 Medium Open Single/Multi 1 30-60° 2.9 

3 41.0 Medium Open Single/Multi 1 60-90° 1.6 

4 0.0 Low Open Multi 2 or 3 0-30° 9.4 

5 0.0 Low Open Single 1 60-90° 4.6 

6a 41.0 Low/Medium Closed Multi Single Vent with Glass 2.3 

6b 0.0 Same as 6a 6.1 

7a 41.0 Medium Closed Single/Multi Glass N/A 2.6 

7b 41.0 Same as 7a, except with only a gravity coil (no fan coil) 1.0 

* IAT = the average temperature of all test packages recorded during testing. 

Source: CSA C657-04, Energy Performance Standard for Refrigerated Display Cabinets (Merchandisers).

3.2.3.4 Australia 

Australia has required efficiency standards for commercial refrigeration equipment since 

October 1, 2004.9 The standards apply to both remote condensing and self-contained 

commercial equipment primarily used to store chilled and frozen food. The minimum energy 

performance standards are established in Australian Standard (AS) 1731.14-2003 as total energy 

consumption per total display area (TEC/TDA) in kWh/day/meter2 (m2) for various equipment 

types. The Australian standards categorize equipment by the following criteria: 

• Remote or self-contained condensing unit 

• Lit shelves or unlit shelves 

• Number of shelves 

• Solid door or glass door 

• Fan coil or gravity coil 

• High, medium, or low temperature 

The standards also specify minimum energy performance by M-package temperatures 

(temperature of a load package) for self-contained cabinets. AS 1731-2003 specifies the test 

procedures used to measure energy consumption. 

3.2.4 Non-Regulatory Initiatives 

DOE reviewed several voluntary programs promoting energy-efficient commercial 

refrigeration equipment in the United States, including the ENERGY STAR program for soliddoor commercial refrigerators and commercial freezers, the Consortium for Energy Efficiency 

(CEE)’s initiative for commercial refrigeration equipment, and the Federal Energy Management 

 EE-2006-STD-0126 COMMENT 23.2
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Program (FEMP)’s procurement program for energy-efficient commercial refrigerators and 

commercial freezers. DOE also reviewed various rebate programs offered by local utilities. 

3.2.4.1 ENERGY STAR 

The ENERGY STAR labeling program has specifications for self-contained solid-door 

commercial refrigerators and commercial freezers, including commercial ice-cream freezers.10

 

This program does not apply to remote condensing commercial equipment or self-contained 

commercial equipment without doors. ENERGY STAR criteria for commercial ice-cream 

freezers specify the maximum energy consumption as follows: 

• Maximum Energy Consumption ≤ 0.39V + 0.82 kWh/day, where V is the internal 

volume in ft3

ENERGY STAR uses the ANSI/ASHRAE Standard 117-1992, Method of Testing Closed 

Refrigerators. Energy consumption tests are conducted with an IAT of -5°F ± 2°F for 

commercial ice-cream freezers. The ENERGY STAR criteria do not mention a test method for 

measuring internal volume. 

3.2.4.2 Consortium for Energy Efficiency 

The CEE has a Commercial Kitchen Initiative for solid door and glass-door reach-in 

commercial refrigerators and commercial freezers.11 This program is based on ENERGY STAR 

levels and only applies to self-contained commercial equipment with doors, and is therefore not 

relevant to this rulemaking. The program specifies standard levels in terms of maximum daily 

energy use in kWh/day for various door types. 

3.2.4.3 Federal Energy Management Program 

FEMP has established purchasing specifications for energy-efficient equipment, 

including commercial ice-cream freezers.12 Federal purchasers are now required by EPACT 

2005 to purchase equipment that is ENERGY STAR qualified or FEMP designated. This 

equipment is in the upper 25 percent of energy efficiency in its class. The coverage of the FEMP 

program is identical to the ENERGY STAR program, and is therefore not relevant to this 

rulemaking. 

3.2.4.4 Rebate Programs 

Several rebate programs for commercial refrigeration equipment are offered by local 

utilities, including Efficiency Vermont, the Energy Smart Grocer Program, the Nevada Sure Bet 

Program, Otter Tail Power Company, Roseville Electric, Pacific Gas and Electric (PG&E), 

Southern California Edison (SCE), and San Diego Gas and Electric (SDG&E). 

Efficiency Vermont, an organization offering technical assistance and financial incentives 

to encourage energy efficiency in Vermont, offers rebates for the installation of strip-curtain 

covers for commercial refrigeration equipment without doors. The cash incentive is $6 per foot 

of display case covered by the curtain.13

 EE-2006-STD-0126 COMMENT 23.2
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The Energy Smart Grocer Program is funded by California utility ratepayers under the 

auspices of the California Public Utilities Commission. Eligible participants include grocery and 

convenience stores, food processors, and refrigerated warehouses operating in PG&E, SCE, or 

SDG&E electric service territories. The program offers rebates for using night covers on 

commercial refrigeration equipment without doors, upgrades to more efficient case lighting, and 

replacing older equipment without doors with new high-efficiency equipment or new or 

refurbished reach-ins.14

Sierra Pacific Power and Nevada Power offer incentives promoting the installation of 

energy-efficient commercial refrigeration equipment through the Nevada Sure Bet Program. 

These rebates are available to the utilities’ commercial, industrial, and institutional customers. In 

addition to other refrigeration rebates, the program offers $4 per linear foot for the installation of 

night covers on commercial refrigeration equipment without doors.15

Otter Tail Power Company offers rebates to Minnesota commercial customers under the 

Conservation Improvement Program. Under this program, customers are eligible to receive 

between $10 and $20 per linear foot of, or upgrade to, high-efficiency commercial refrigeration 

equipment.16

Roseville Electric has a Custom Rebate program that includes commercial refrigeration 

equipment. The customer is paid for energy-efficiency projects that reduce peak kW; however, 

no rebates are paid on kWh savings. In this type of rebate, customers or their engineers present 

the project scope, including what equipment is currently installed, what is proposed, and how the 

proposed equipment goes beyond what would be considered standard for today’s replacement. 

Engineering calculations are provided to show kW and kWh savings. Roseville Electric 

evaluates the customer’s proposal and advises if the project is eligible for rebates and at what 

level. Typically, rebates are paid at $400/kW, but may be less if significant third-party 

engineering work is required to verify the peak load reductions.17

PG&E, SCE, and SDG&E offer rebates to business customers for retrofit refrigeration 

projects through the Express Efficiency Refrigeration Program. The program provides $9 per 

linear foot for night covers installed on existing commercial refrigeration equipment without 

doors to all business customers. The program also gives incentives for the installation of glass 

doors on existing equipment without doors. This rebate is applicable to both self-contained 

commercial equipment and remote condensing commercial equipment. The rebate provides $200 

per door installed on an otherwise open low-temperature display case and $150 per door installed 

on a medium-temperature display case.18, 19, 20 

3.2.5 Equipment Classes 

Commercial refrigeration equipment can be divided into various equipment classes 

categorized by physical characteristics that affect equipment efficiency. Most of these 

characteristics affect the merchandise that the equipment can be used to display, and how the 

customer can access that merchandise. Key physical characteristics are the operating 

temperature, the presence or absence of doors (i.e., closed cases or open cases), the type of doors 

used (i.e., transparent or solid), the angle of the door or air curtain (i.e., horizontal, semivertical, 

or vertical), and the type of condensing unit (i.e., remote or self-contained). The following list 

 EE-2006-STD-0126 COMMENT 23.2
3-14

shows the key physical characteristics of commercial refrigeration equipment that DOE 

identified in its Framework Document: 

1. Operating Temperature 

• Medium temperature (38°F, refrigerators) 

• Low temperature (0°F, freezers) 

• Ice-cream temperature (-15°F, ice-cream freezers) 

2. Door Type 

• Equipment with transparent doors 

• Equipment with solid doors 

• Equipment without doors 

3. Orientation (air-curtain or door angle) 

• Horizontal 

• Semivertical 

• Vertical 

4. Type of Condensing Unit 

• Remote condensing 

• Self-contained 

ARI proposed another organization of equipment classes for commercial refrigeration 

equipment during the Framework comment period. ARI organized classes by equipment family 

(broad groups of covered equipment that have similar geometric characteristics), condensing unit 

type, and operating temperature. The equipment families ARI identified are: 

• vertical without doors (air-curtain angle of 0 to 10° from the vertical); 

• semivertical without doors (air-curtain angle of 10 to 80° from the vertical); 

• horizontal without doors (air-curtain angle of 80 to 90° from the vertical); 

• vertical with doors; 

• horizontal with doors; and 

• service over-counter. 

One equipment family ARI proposed, “service over-counter,” was not included in the 

DOE organization of equipment classes. This equipment is unique because it is designed to 

display products, but access to the products is from the back of the cabinet. Such equipment is 

designed to display products that typically only sales personnel have access to. This equipment 

family is necessary, as this type of equipment provides a different utility to the end-user than any 

of the other proposed classes. 

ARI’s organization also differentiates equipment by operating temperature. Because not 

all models can be tested at one of the three temperatures DOE proposed (medium, low, and icecream), ARI proposed a third temperature category: an “application” temperature. 

DOE examined the shipment data ARI provided (section 3.2.6) to determine how much 

equipment operates at an application temperature and how much operates at one of the three 

temperatures DOE proposed. Excluding equipment for which EPACT 2005 amended EPCA to 

set standards (self-contained commercial refrigerators and commercial freezers with doors), 

 EE-2006-STD-0126 COMMENT 23.2
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170,949 units of remote condensing and self-contained equipment were shipped in 2005. 

(Shipments of commercial refrigerator-freezers were not reported, but are considered very 

small.) Of the total shipments, only 1.7 percent were self-contained and remote condensing 

equipment that operate at 45°F, 20°F, 10°F, or -30°F (application temperatures), and 98.3 

percent were self-contained and remote condensing equipment that operate at 38°F, 0°F, or -

15°F. By far, the application temperature with the largest number of units shipped is the 45°F 

category (typically wine chillers), and these were predominately remote condensing equipment. 

In all, 1,834 units of remote condensing wine chillers were shipped in 2005, compared to 85,001 

units of remote condensing refrigerators that operate at 38°F. 

DOE’s test procedure for commercial refrigeration equipment (Chapter 2) requires that 

all equipment, including equipment designed to operate at application temperatures, be tested at 

one of the three rating temperatures: 38°F for refrigerators, 0°F for freezers, and -15°F for icecream freezers. Given the relatively low shipment volumes of equipment that operates at 

application temperatures, that some of this equipment already can operate and be tested at one of 

the standard rating temperatures, and that manufacturers might be able to redesign other 

equipment in relatively minor ways to have these capabilities, DOE believes this requirement 

will not place an unreasonable burden on manufacturers. If necessary, manufacturers could seek 

waivers from the DOE test procedure, pursuant to 10 CFR 431.401. For these reasons, DOE will 

not develop separate standards for equipment that operates at application temperatures. 

DOE is organizing its equipment classes in a manner similar to ARI’s, and used the six 

ARI equipment families as a starting point to develop a list of equipment classes. The “vertical 

with doors” equipment class and the “horizontal with doors” equipment class were split into two 

each based on having either transparent or solid doors. Table 3.2.4 shows the eight commercial 

refrigeration equipment families DOE proposed. 

 EE-2006-STD-0126 COMMENT 23.2
3-16

Table 3.2.4 Commercial Refrigeration Equipment Families 

Equipment Family Designation Description 

Vertical Open VOP Equipment without doors and an air-curtain angle ≥ 0° and 

< 10° 

Semivertical Open SVO Equipment without doors and an air-curtain angle ≥ 10° 

and < 80° 

Horizontal Open HZO Equipment without doors and an air-curtain angle ≥ 80° 

Vertical Closed Transparent VCT Equipment with hinged or sliding transparent doors and a 

door angle < 45° 

Vertical Closed Solid VCS Equipment with hinged or sliding transparent doors and a 

door angle ≥ 45° 

Horizontal Closed Transparent HCT Equipment with hinged or sliding solid (opaque) doors 

and a door angle < 45° 

Horizontal Closed Solid HCS Equipment with hinged or sliding solid (opaque) doors 

and a door angle ≥ 45° 

Service Over Counter SOC 

Equipment with sliding or hinged doors intended for use 

by sales personnel and fixed or hinged glass for displaying 

merchandise 

Within each of these eight equipment families is equipment that can have one of two 

condensing unit types and one of three operating temperatures. The condensing unit type has a 

significant impact on utility and energy use, and can be either remote condensing (RC) or selfcontained (SC). Remote condensing equipment is typically more efficient than self-contained 

because of the use of large, multiplex compressor rack systems that feed multiple pieces of 

equipment. Remote condensing equipment cannot be easily relocated, due to the refrigerant 

piping required, whereas self-contained equipment is more mobile, requiring only an electrical 

outlet for operation. 

The operating temperature of the equipment also has a significant impact on utility and 

energy use, and can be medium (M), low (L) or ice-cream (I), representing a rating temperature 

(or IAT) of 38°F, 0°F, or -15°F, respectively (± 2°F). Because different types of merchandise 

require different temperatures (e.g., chilled and frozen), operating temperature was a necessary 

distinction. The larger temperature differences and thermodynamic behavior of refrigerants 

means that equipment with lower operating temperatures runs less efficiently than equipment 

with higher operating temperatures. 

For open cases, “vertical” represents an air-curtain angle of < 10° from the vertical, 

“semivertical” represents an air-curtain angle of ≥ 10° and < 80° from the vertical, and 

“horizontal” represents an air-curtain angle of ≥ 80° from the vertical. DOE could not identify 

an existing industry definition of air-curtain angle, but developed a preliminary definition for 

consideration: “the angle between a vertical line and the line formed by the points at the center of 

the discharge air grille and the center of the return air grille when viewed in cross-section.” 

For closed cases, “vertical” represents a door angle of < 45° from the vertical, and 

“horizontal” represents a door angle of ≥ 45° from the vertical. DOE did not receive stakeholder 

feedback on how to define the door angle for equipment with doors, but is defining door angle as 

 EE-2006-STD-0126 COMMENT 23.2
3-17

“the angle between a vertical line and the line formed by the plane of the door when viewed in 

cross-section.” 

Using all combinations of equipment families, operating mode and temperature, 48 

equipment classes are possible, as illustrated in Table 3.2.5. However, self-contained equipment 

with doors that operate at a medium temperature, low temperature, or both, already had standards 

established in EPACT 2005. Therefore, these ten equipment classes were not included in this 

rulemaking and are indicated by asterisks in Table 3.2.5. 

DOE also developed a lettering system to simplify discussion of equipment classes. The 

lettering designation for a particular equipment class consists of the abbreviations for the 

equipment family, operating mode, and temperature, separated by periods. Table 3.2.5 shows a 

complete list of equipment classes with lettering designations organized by family, operating 

mode, and temperature. 

 EE-2006-STD-0126 COMMENT 23.2
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Table 3.2.5 Commercial Refrigeration Equipment Classes 

Equipment Family 

Equipment 

Family 

Designation 

Equipment 

Family Image 

Operating 

Mode 

Designation 

Temperature 

Designation 

Equipment Class 

Designation 

M (38°F) VOP.RC.M 

RC L (0°F) VOP.RC.L 

I (-15°F) VOP.RC.I 

M (38°F) VOP.SC.M 

L (0°F) VOP.SC.L 

Vertical Open VOP 

SC 

I (-15°F) VOP.SC.I 

M (38°F) SVO.RC.M 

RC L (0°F) SVO.RC.L 

I (-15°F) SVO.RC.I 

M (38°F) SVO.SC.M 

L (0°F) SVO.SC.L 

Semivertical Open SVO 

SC 

I (-15°F) SVO.SC.I 

M (38°F) HZO.RC.M 

RC L (0°F) HZO.RC.L 

I (-15°F) HZO.RC.I 

M (38°F) HZO.SC.M 

L (0°F) HZO.SC.L 

Horizontal Open HZO 

SC 

I (-15°F) HZO.SC.I 

M (38°F) VCT.RC.M 

RC L (0°F) VCT.RC.L 

I (-15°F) VCT.RC.I 

M (38°F) VCT.SC.M* 

L (0°F) VCT.SC.L* 

Vertical Closed 

Transparent VCT 

SC 

I (-15°F) VCT.SC.I 

M (38°F) VCS.RC.M 

RC L (0°F) VCS.RC.L 

I (-15°F) VCS.RC.I 

M (38°F) VCS.SC.M* 

L (0°F) VCS.SC.L* 

Vertical Closed Solid VCS 

SC 

I (-15°F) VCS.SC.I 

M (38°F) HCT.RC.M 

RC L (0°F) HCT.RC.L 

I (-15°F) HCT.RC.I 

M (38°F) HCT.SC.M* 

L (0°F) HCT.SC.L* 

Horizontal Closed 

Transparent HCT 

SC 

I (-15°F) HCT.SC.I 

M (38°F) HCS.RC.M 

RC L (0°F) HCS.RC.L 

I (-15°F) HCS.RC.I 

M (38°F) HCS.SC.M* 

L (0°F) HCS.SC.L* 

Horizontal Closed 

Solid HCS 

SC 

I (-15°F) HCS.SC.I 

M (38°F) SOC.RC.M 

RC L (0°F) SOC.RC.L 

I (-15°F) SOC.RC.I 

M (38°F) SOC.SC.M* 

L (0°F) SOC.SC.L* 

Service Over Counter SOC 

SC 

I (-15°F) SOC.SC.I 

* These equipment classes have standards established by EPACT 2005 and are therefore not covered under this rulemaking. 

 EE-2006-STD-0126 COMMENT 23.2
3-19

3.2.6 Shipments 

As part of its comments on the Framework Document (ARI, No. 7 Exhibit B at p. 1), ARI 

submitted annual shipment data by equipment class for its member companies. DOE 

understands that these data do not include the entire industry, since ARI does not represent all 

major manufacturers.e However, because these data cover the vast majority of the remote 

condensing equipment sold, and because no other detailed data were available, the ARI shipment 

data became the basis of DOE’s analysis. 

Table 3.2.6 shows 2005 annual shipments for each category of commercial refrigeration 

equipment by equipment class. The ARI data included shipments for equipment that operates at 

an “application” temperature (e.g., wine chillers that operate at 45°F and freezers that operate at -

30°F). However, DOE only considered shipments of equipment at the three temperatures 

considered in this rulemaking (38°F, 0°F, and -15°F; see section 3.2.5). The shipments of 

equipment that operate at one of these three temperatures constitute approximately 98 percent of 

the shipments ARI reported. 

 

e

 Most notably, True Manufacturing, which DOE understands has a large market share of self-contained equipment 

with doors and ice-cream freezers. 

 EE-2006-STD-0126 COMMENT 23.2
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Table 3.2.6 Air-Conditioning and Refrigeration Institute Shipments of Commercial 

Refrigerators and Freezers by Equipment Class 

Equipment 

Family 

Equipment 

Family 

Designation 

Operating 

Mode 

Designation 

Temperature 

Designation 

Equipment Class 

Designation ARI Shipments** 

M (38°F) VOP.RC.M 38,743 

RC L (0°F) VOP.RC.L 0 

I (-15°F) VOP.RC.I 0 

M (38°F) VOP.SC.M 6,512 

L (0°F) VOP.SC.L 0 

Vertical Open VOP 

SC 

I (-15°F) VOP.SC.I 0 

M (38°F) SVO.RC.M 29,552 

RC L (0°F) SVO.RC.L 0 

I (-15°F) SVO.RC.I 0 

M (38°F) SVO.SC.M 9,750 

L (0°F) SVO.SC.L 0 

Semivertical Open SVO 

SC 

I (-15°F) SVO.SC.I 0 

M (38°F) HZO.RC.M 4,541 

RC L (0°F) HZO.RC.L 14,278 

I (-15°F) HZO.RC.I 0 

M (38°F) HZO.SC.M 838 

L (0°F) HZO.SC.L 1,738 

Horizontal Open HZO 

SC 

I (-15°F) HZO.SC.I 0 

M (38°F) VCT.RC.M 2,767 

RC L (0°F) VCT.RC.L 38,483 

I (-15°F) VCT.RC.I 0 

M (38°F) VCT.SC.M* 43,374* 

L (0°F) VCT.SC.L* 2,472* 

Vertical Closed 

Transparent VCT 

SC 

I (-15°F) VCT.SC.I 1,898 

M (38°F) VCS.RC.M 49 

RC L (0°F) VCS.RC.L 2 

I (-15°F) VCS.RC.I 43 

M (38°F) VCS.SC.M* 4* 

L (0°F) VCS.SC.L* 4,202* 

Vertical Closed 

Solid VCS 

SC 

I (-15°F) VCS.SC.I 470 

M (38°F) HCT.RC.M 0 

RC L (0°F) HCT.RC.L 15 

I (-15°F) HCT.RC.I 0 

M (38°F) HCT.SC.M* 724* 

L (0°F) HCT.SC.L* 0* 

Horizontal Closed 

Transparent HCT 

SC 

I (-15°F) HCT.SC.I 9,056 

M (38°F) HCS.RC.M 37 

RC L (0°F) HCS.RC.L 0 

I (-15°F) HCS.RC.I 0 

M (38°F) HCS.SC.M* 39,761* 

L (0°F) HCS.SC.L* 4,109* 

Horizontal Closed 

Solid HCS 

SC 

I (-15°F) HCS.SC.I 0 

M (38°F) SOC.RC.M 9,312 

RC L (0°F) SOC.RC.L 9 

I (-15°F) SOC.RC.I 0 

M (38°F) SOC.SC.M* 1,108* 

L (0°F) SOC.SC.L* 0* 

Service Over 

Counter SOC 

SC 

I (-15°F) SOC.SC.I 0 

* These equipment classes have standards established by EPACT 2005 and are therefore not covered under this rulemaking. 

** Source: ARI, No. 7 Exhibit B at p. 1.

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3.2.6.1 Appliance Magazine Data 

Appliance Magazine publishes historical and forecasted shipments of refrigerated display 

cases, shown in Table 3.2.7 and Table 3.2.8.f For this rulemaking, only the self-contained 

equipment without doors and all remote condensing equipment are applicable. 

Table 3.2.7 Historical Shipments of Refrigerated Display Cases 

Year Unit Shipments 

1996 316,500 

1997 324,000 

1998 302,625 

1999 340,453 

2000 347,262 

2001 175,000 

2002 183,300 

2003 191,549 

2004 185,000 

2005 170,000 

Source: Appliance Magazine, “53rd Annual Statistical Review,” May 2006. 

Table 3.2.8 Statistical Forecasts of Refrigerated Display-Case Shipments 

Year Unit Shipments 

2007 181,000 

2008 185,000 

Source: Appliance Magazine, “54th Appliance Industry Forecasts,” January 2006. 

It is unclear what is responsible for the sharp decline in unit shipments between 2000 and 

2001 reported by Appliance Magazine. A similar decline is reported in other market literature, 

followed by an increase in shipments predicted by 2008.21 DOE believes that some fraction of 

the observed decline in shipments is the result of a general slowdown in the U.S. economy in the 

second and third quarters of 2001. Financial reports by CRE manufacturers discuss depressed 

investment and uncertainty in the retail food industry between 2000 and 2005 as contributing 

factors to low sales of commercial refrigeration equipment. There may be other explanations, 

including possible changes in what equipment Appliance Magazine included in “refrigerated 

display cases.”

3.2.6.2 Current Industrial Reports 

The U.S. Census Bureau’s Economic Census of Manufacturing Industry Series and its 

Current Industrial Reports (CIRs) publish statistics on the quantity and value of shipments for 

those companies with shipments over $100,000 in value.22,23 There are eight categories for 

 

f

 As mentioned earlier, Appliance Magazine describes the data as representing refrigerated display cases but does 

not provide a precise definition of the equipment. It is unclear what types of equipment this term covers–whether it 

is equipment that is self-contained or remote condensing, or equipment with doors or without doors. 

 EE-2006-STD-0126 COMMENT 23.2
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display cabinets and display cases, including reach-ins. These are sub-divided into reach-in, 

closed display, and open display. As the tables below show, the data reported in the CIRs are not 

complete (i.e., shipments data are not provided for most sub-categories).g The data also indicate 

some very large changes in the value of shipments in 1992, 1997, and 2002. 

Table 3.2.9 shows shipment data for open refrigerated display cases, which include both 

self-contained units without doors and remote condensing units without doors. It is not possible 

to determine from Table 3.2.9 which shipments are for self-contained units and which are for 

remote condensing units since the census data reports these together. Only the self-contained 

open refrigerated display cases and remote condensing open refrigerated display cases are 

applicable to this rulemaking. 

Table 3.2.9 Shipments of Open Refrigerated Display Cases (Remote Condensing and SelfContained) 

Type Open or 

Closed Temperature Survey Year

Number of 

Companies with 

Sales Over 

$100,000 

Shipment 

Quantity 

(1,000s) 

Shipment 

Value 

($1,000) 

2002 6 - 89,622 

1997 13 - 140,259 

Display Case 

One Level Open Normal 

1992 12 - 142,268 

2002 9 - 341,472 

1997 11 58.6 258,310 

Display Case 

Multi Level Open Normal 

1992 9 - 151,760 

2002 6 - 11,538 

Display Case Open Frozen Food 1997 7 20.4 90,213 

1992 8 -- 61,776 

Source: U.S. Census, Current Industrial Reports, http://www.census.gov/cir/www/index.html; U.S. Census, Economic Census, Manufacturing 

Industry Series 1997, EC97M-3334D, http://www.census.gov/epcd/www/97EC31.HTM: U.S. Census, Economic Census, Manufacturing 

Industry Series 2002, EC02-31I-333415 (RV), http://www.census.gov/econ/census02. 

Table 3.2.10 shows shipment data for closed refrigerated display cases, which include 

both self-contained units with doors and remote condensing units with doors. It is not possible to 

determine from Table 3.2.10 which shipments are for remote condensing units. Only the remote 

condensing closed refrigerated display cases are covered in this rulemaking. 

 

g

 Shipments are not typically published for equipment with low shipments or shipments from only a small number of 

manufacturers in order to protect business sensitive information. 

 EE-2006-STD-0126 COMMENT 23.2
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Table 3.2.10 Shipments of Closed Refrigerated Display Cases (Remote Condensing and 

Self-Contained) 

Type Open or 

Closed Temperature Survey Year

Number of 

Companies with 

Sales Over 

$100,000 

Shipment 

Quantity 

(1,000s) 

Shipment 

Value 

($1,000) 

2002 11 - 50,601 

Display Case Closed Normal 1997 15 - 91,892 

1992 14 - 43,576 

2002 8 - 20,618 

Cabinet Closed Frozen Food 1997 9 - 112,873 

1992 6 38,171 

2002 7 - 58,549 

1997 6 - 43,150 

Other 

Display 

Cases 

Not stated Low Temp. 

1992 9 9.6 39,629 

Source: U.S. Census, Current Industrial Reports, http://www.census.gov/cir/www/index.html; U.S. Census, Economic Census, Manufacturing 

Industry Series 1997, EC97M-3334D, http://www.census.gov/epcd/www/97EC31.HTM: U.S. Census, Economic Census, Manufacturing 

Industry Series 2002, EC02-31I-333415 (RV), http://www.census.gov/econ/census02. 

For the data in Table 3.2.9 and Table 3.2.10, the following two commercial refrigeration 

equipment sub-categories are not included: 

• Commercial reach-in refrigerators and reach-in vertical display cabinets for normal 

temperature applications (not intended for frozen foods, etc.), including selfcontained and remote units. 

• Commercial reach-in refrigerators and reach-in type vertical display cabinets for lowtemperature applications, including self-contained and remote units. 

Table 3.2.11 shows shipment data for commercial reach-in (vertical) cabinets (including 

self-contained units and remote condensing units). These cabinets can have either solid or 

glazed doors. It is not possible to determine from Table 3.2.11 which shipments are for remote 

condensing units and which shipments are for self-contained units. Only the remote condensing 

reach-in cabinets are covered in this rulemaking.

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Table 3.2.11 Shipments of Commercial Reach-In Cabinets (Remote Condensing and SelfContained) 

Type Open or 

Closed Temperature Survey Year

Number of 

Companies with 

Sales Over 

$100,000 

Shipment 

Quantity 

(1,000s) 

Shipment 

Value 

($1,000) 

2002 21 381.7 465,553 

1997 29 - 439,081 

Display 

Cabinets - 

Not for 

Frozen 

Foods 

Not 

Specified Normal 

1992 31 165.8 224,018 

2002 16 - 259,105 

1997 24 - 307,605 

Display 

Cabinet 

Not 

Specified 

Low 

Temperature 

1992 24 59.5 219,544 

Source: U.S. Census, Current Industrial Reports, http://www.census.gov/cir/www/index.html; U.S. Census, Economic Census, Manufacturing 

Industry Series 1997, EC97M-3334D, http://www.census.gov/epcd/www/97EC31.HTM: U.S. Census, Economic Census, Manufacturing 

Industry Series 2002, EC02-31I-333415 (RV), http://www.census.gov/econ/census02. 

 In summary, although the U.S. Census Bureau Data contain some limited shipments data 

that would be useful for conducting technical analyses, not enough detail is available to provide 

specific assessments for shipments within each of the three primary categories covered in this 

rulemaking. 

3.2.7 Equipment Lifetimes 

DOE reviewed available literature and consulted with experts on commercial 

refrigeration equipment to establish typical equipment lifetimes. The literature and individuals 

consulted estimated a wide range of typical equipment lifetimes, shown in Table 3.2.12. 

Individuals with previous experience in the manufacture or distribution of commercial 

refrigeration equipment suggested a typical case life of 5 to 15 years. Experts in the field 

suggested that while the equipment is typically robust in design, much of the equipment is 

replaced for cosmetic reasons during store remodeling (typically every 10 years or so). 

Consultation with one distributor suggested that U.S. tax depreciation schedules, which allow 

depreciation over a 5-year period for retail fixtures, including commercial refrigerators and 

commercial freezers,24 are one driver for regular replacement of commercial refrigeration 

equipment in the United States. 

Some literature suggested lifetimes of up to 20 years or more for commercial 

refrigeration equipment. Many of the studies cited here related to examination of environmental 

impacts of refrigerant emissions and therefore may not always clearly distinguish between the 

lifetime of the case and the lifetime of the compressor racks.25 However, consultation with 

experts in the field suggested that smaller, independently owned grocery stores were more likely 

to keep equipment longer than larger chain stores. 

Several industry experts suggested there is a significant used/refurbished equipment 

market. However, DOE did not determine the size of the used market relative to the new market. 

Those consulted generally agreed that the salvage value of used equipment was very low 

compared to the initial purchase price. This is due to both cosmetic concerns and the custom 

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nature of much of the equipment. The difficulty in collecting used equipment of the same “look” 

for planned display case line-ups was cited as another reason for the low price of used 

equipment. A survey in the Pacific Northwest reported that for small, independent grocery stores 

(<20,000 square feet) and independently owned convenience stores, the fraction of owners who 

would consider purchase of refurbished equipment was 25 and 16 percent, respectively. For 

larger regional chains, this fraction was approximately 11 percent. None of the large grocery 

chains surveyed had plans to purchase refurbished equipment. 

Table 3.2.12 Estimates for Commercial Refrigeration Equipment Lifetimes 

Life Reference 

15 years “New York Energy Smart Program Cost-Effectiveness Assessment” 

December 2004, NYSERDA26

5-7 years 

(large chains) 

Verisae27

15 years 

(Smaller chains and independent 

grocers. May go up to 20 years) 

Verisae28 

7-15 years Mark Ellis & Associates,29 New Zealand Minimum Energy Performance 

Standards for Commercial Refrigeration Cabinets 

15 years Foster-Miller (2001)30 

15-20 years EPA (2001)31

15 years Arthur D. Little (ADL) (2002)32 

9-10 years 

(9 years with doors, 10 years 

without doors) 

CEC 200433 

5-15 years (typically 10 years) Hansen 200634 

10 years PG&E 20043 

7-10 years (remote condensing) 

8-12 years (self-contained) 

Intergovernmental Panel on Climate Change 200135

7 years Fisher 199136

3.2.8 Market Performance Data 

DOE conducted a survey of existing remote condensing refrigerated equipment from 

major manufacturers and compiled a performance database. The primary source of information 

for the database was equipment data sheets that were publicly available on manufacturers’ 

websites. From these data sheets, equipment information such as total refrigeration load, 

evaporator temperature, lighting power draw, defrost power draw, and motor power draw 

allowed determination of calculated daily energy consumption (CDEC) according to the test 

procedure in ARI Standard 1200-2006, Performance Rating of Commercial Refrigerated Display 

Merchandisers and Storage Cabinets. Figure 3.2.2 through Figure 3.2.5 show CDEC values as a 

function of TDA for select remote condensing equipment classes. Figure 3.2.6 shows the 

relationship between air-curtain angle (measured from the vertical) and CDEC/TDA for the 

VOP.RC.M, SVO.RC.M, and HZO.RC.M equipment classes. 

 

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Figure 3.2.2 Market Performance Data for the VOP.RC.M Equipment Class 

Figure 3.2.3 Market Performance Data for the SVO.RC.M Equipment Class 

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Figure 3.2.4 Market Performance Data for the HZO.RC.M Equipment Class 

Figure 3.2.5 Market Performance Data for the VCT.RC.L Equipment Class 

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Figure 3.2.6 Market Performance Data for the VOP.RC.M, SVO.RC.M, and 

HZO.RC.M Equipment Classes: Comparison of Air-Curtain Angles 

3.3 TECHNOLOGY ASSESSMENT 

The purpose of the technology assessment is to develop a preliminary list of technologies 

that could potentially be used to improve the efficiency of commercial refrigeration equipment. 

The following assessment provides descriptions of technologies and designs that apply to all 

equipment classes; designs that apply to equipment without doors only; and technologies and 

designs that apply to self-contained equipment only. 

3.3.1 Technologies and Designs Relevant to All Equipment Classes 

The following technologies and designs are relevant to all equipment classes: higher 

efficiency lighting, higher efficiency ballasts, remote ballast location, higher efficiency 

expansion valves, higher efficiency evaporator fan motors, evaporator fan motor controllers, 

higher efficiency evaporator fan blades, increased evaporator surface area, low-pressure 

differential evaporators, anti-sweat heater controllers, insulation increases or improvements, 

defrost mechanism, and defrost cycle control. 

3.3.1.1 Higher Efficiency Lighting 

Commercial refrigeration equipment often includes lighting to illuminate the contents. 

Some commercial refrigeration equipment also includes an illuminated sign on the unit’s 

exterior. Higher efficiency lighting leads to energy savings in two ways: less energy is used 

directly for lighting, and less heat energy is dissipated into the refrigerated case by the lamp. 

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Efficiency in lighting is commonly measured as efficacy (lumens/watt), or the quantity of light 

output (lumens) per electrical energy input (watts, W). 

Recently, the commercial refrigeration industry has been moving toward using T8 

fluorescent lighting in all cases. T8 lighting is substantially more efficacious than T12 lighting 

and is predominantly used with electronic ballasts, which are more efficient than magnetic 

ballasts commonly used in T12 lighting. The industry is also increasingly interested in T5 

lighting, although T5 lighting systems are not significantly more efficacious than T8 systems. 

An even more recent trend is the use of light emitting diode (LED) technology. Although 

LEDs are less efficacious than fluorescent technology, they are more directional than linear 

fluorescent bulbs, allowing for comparable product illumination with less total wattage. There 

have been recent advancements in LED efficacy and large food retailers have adopted LED 

technology.37 Research by the Lighting Resource Center indicates that consumers found lighting 

in display cases using LEDs desirable. DOE predicts that LEDs will steadily increase in efficacy 

and decrease in cost as technology improves.38

3.3.1.2 Higher Efficiency Lighting Ballasts 

Higher efficiency lighting ballasts reduce energy consumption by requiring less electrical 

power to operate, and by reducing waste heat generation, which contributes to case heat load. 

Most illuminated display cases in supermarkets use fluorescent lighting with magnetic 

ballasts, which use inductance to modulate power flow to fluorescent lamps. Magnetic ballasts 

have significant electrical resistance losses. Electronic ballasts use solid state electronics to 

modulate power provided to fluorescent lamps. Electronic ballasts, which convert power at high 

frequency, have lower electrical resistance losses compared to magnetic ballasts, which operate 

at line frequency. Fluorescent lamps also operate more efficiently at the higher frequency 

provided by electronic ballasts. 

In addition to the direct reductions in electrical power consumption, heat generated by the 

lighting and the lighting ballast contribute to the case heat load. Increasing ballast efficiency 

also reduces the compressor load. 

3.3.1.3 Remote Lighting Ballast Location 

Because lamp ballasts may be located apart from the fluorescent lamps they power, they 

may be within the display case cabinet but outside of the refrigerated space, reducing heat load 

and case energy consumption. 

3.3.1.4 Higher Efficiency Expansion Valves 

Expansion valves are refrigerant metering devices that control the amount of refrigerant 

flowing to the evaporator coil. In doing so, they simultaneously decrease the temperature and 

pressure of the refrigerant, creating a cold liquid-vapor mixture. The low temperature of the 

refrigerant leaving the expansion valve creates the driving force to move heat out of the 

refrigerated space and into the evaporator. 

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The most basic type of expansion device is a capillary tube, which may be found in small 

self-contained commercial refrigeration equipment. The capillary tube is a long, thin piece of 

pipe that creates a pressure drop in the refrigerant through frictional losses. Capillary tubes must 

be sized to the particular application and cannot adjust for variations in load or ambient operating 

conditions. They are often oversized for worst-case conditions, and therefore may operate at 

reduced efficiency during normal operation. 

The thermostatic expansion valve (TXV) is common in remote condensing commercial 

refrigeration equipment. This device uses an orifice to reduce the pressure of the entering 

refrigerant and a sensing bulb to monitor and maintain the temperature of the superheated vapor 

leaving the evaporator. Because the TXV allows for some degree of adjustment of refrigerant 

expansion, it may be somewhat more efficient than the capillary tube device under varying 

conditions. However, a TXV will likely not provide significant energy savings over a properly 

sized capillary tube under steady-state conditions. 

The electronic expansion valve (EEV) is similar to the TXV, but uses an electronic 

control system to optimize refrigeration-system performance under all operating conditions. 

Because it does this with greater flexibility than a TXV allows, an EEV theoretically allows for 

increases in energy efficiency under varying conditions. However, as with the TXV, an EEV 

will likely not provide significant energy savings over a properly sized capillary tube or a TXV 

under steady-state conditions. 

3.3.1.5 Higher Efficiency Evaporator Fan Motors 

Evaporator fan motors are fractional horsepower in size, are responsible for moving air 

across the evaporator coil, and typically run at one speed. The manufacturer will match the 

motor size and blade to the evaporator coil to meet the expected load on the case under most 

conditions. Higher efficiency evaporator fan motors reduce energy consumption by requiring 

less electrical power to generate motor shaft output power. 

Electric motors operate based on the interaction between a field magnet and a magnetic 

rotor. In a brushed motor, the field magnets are permanent magnets and the rotor is an 

electromagnet; the situation is reversed in a brushless motor. The electromagnetic interactions 

between these two magnets cause the rotor to rotate. 

Single-phase, the simplest type of electric motors, suffer from a serious shortcoming. 

Single-phase motors only produce a rotating magnetic field when the rotor is rotating, and 

simply powering the electromagnet is therefore not sufficient to start such a motor. One of the 

most significant differences between different types of single-phase motors is the way in which 

they handle this start-up problem. 

Nearly all inexpensive fan motors are of either shaded-pole or permanent split capacitor 

(PSC), and the same is most likely true for standard commercial refrigeration equipment fan 

motors (fan motors not marketed as “high efficiency”). In both cases, the electromagnet consists 

of windings of electrical wire through which current is driven. In a shaded-pole motor, a portion 

of these windings is “shaded” by a copper loop. The interactions between the magnetic field 

generated by the shaded portion and that generated by the un-shaded portion induce rotation 

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when the motor is powered. Because the imbalance between the shaded and unshaded portions 

of the magnet remains throughout operation, however, shaded-pole motors are inefficient, with 

typical motor efficiencies less than 20 percent.39 Shaded-pole motors are, however, electrically 

simple and inexpensive. 

In a PSC motor, a smaller, start-up winding is present in addition to the main winding. 

The start-up winding is electrically connected in parallel with the main winding and in series 

with a capacitor. At start up, the interactions between the magnetic field generated by the startup winding and that generated by the main winding induce rotation. Because of the capacitor, 

however, the current to the start-up winding is cut off as the motor reaches steady state. Because 

of this, PSC motors are more energy efficient than their shaded-pole counterparts, with motor 

efficiencies ranging from 50 to 70 percent. Like shaded-pole motors, PSC motors are produced 

in large quantities and are relatively inexpensive.40 The energy efficiency of commercial 

refrigeration equipment fans that use shaded-pole motors can be substantially improved by 

replacing them with PSC motors. 

A third type of electric motor, the electronically commutated permanent magnet (ECM) 

motor (also known as the brushless permanent magnet motor), is more energy-efficient than 

either shaded-pole or PSC motors. ECM motors, which are sold in high volumes, are threephase electric motors with efficiencies even greater than PSC motors. However, ECM motors 

can weigh about twice as much and are more expensive than equivalent PSC motors. 

3.3.1.6 Evaporator Fan Motor Controllers 

Evaporator fan motor controllers allow fan motors to run at variable speed to match 

changing conditions in the case. During periods of frost build-up, fan motor power requirements 

increase; during the post-defrost period, power requirements decrease. Matching the fan speed 

to all conditions ensures more stable discharge air temperatures (and thus more stable product 

temperatures) and improves coil performance. Evaporator fan motor controllers would also 

allow the case to run more efficiently at different ambient humidity and temperature levels. 

3.3.1.7 Higher Efficiency Evaporator Fan Blades 

High-efficiency evaporator fan blades, or tangential evaporator fans, move air more 

efficiently, yielding energy consumption savings by reducing the required fan shaft power. The 

evaporator fans typically used in commercial refrigeration equipment have sheet metal blades. 

Usually, the fan blade manufacturer supplies the blades and the equipment manufacturer mounts 

them. These fan blades are not optimized for commercial refrigeration equipment. Evaporator 

fans may have lower efficiencies due to the higher required pressure drops, for which sheet metal 

fans are not well suited. Required fan shaft power could be reduced if the fan blades were 

optimized for each application.

Tangential fans also provide an opportunity to decrease equipment energy consumption.41 

Tangential fans use a vortex builder to generate a uniform airflow over a large surface. This 

makes them better suited to evaporator and condenser fans, which need to distribute airflow over 

a large coil surface area. A single long tangential fan can meet the airflow requirements for an 

entire refrigerated cabinet, and require only one high-efficiency fan motor. 

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3.3.1.8 Increased Evaporator Surface Area 

The evaporator is a refrigerant-to-air heat exchanger composed of metals with high 

thermal conductivity such as aluminum and copper. It is responsible for evaporating and 

superheating the entering refrigerant liquid-vapor mixture while extracting heat from the air in 

the refrigerated space. The internal heat-exchanging surfaces in contact with refrigerant are 

commonly referred to as “refrigerant-side,” while the external heat-exchanging surfaces in 

contact with the air are referred to as “air-side.” 

Depending on the requirements of the equipment, the evaporator will have a discharge air 

temperature (DAT) that can be up to 10°F colder than the desired temperature of the product. 

Because a temperature difference is necessary to drive heat from the air into the refrigerant, the 

saturated evaporator temperature (SET) must be considerably colder than the DAT. The 

magnitude of this driving force is directly related to the total refrigeration load and the thermal 

characteristics of the evaporator, as shown in Equation 3.1: 

UA

Q

TSETDAT =∆=− Eq. 3.1 

where 

Q is the total refrigeration load (Btu/h), 

U is the heat transfer coefficient of the evaporator (Btu/°F/ft2), 

A is the area of the evaporator (ft2), and 

∆T is the temperature difference between the discharge air temperature and evaporator 

temperature (°F). 

Increasing the area of the coil will decrease the necessary ∆T and therefore decrease the SET. 

This results in an increased compressor energy efficiency ratio (EER) and lower compressor 

energy consumption. 

Enhancements to the refrigerant-side surface area of the evaporator typically include 

rifled or diamond-pattern tubing and increased number of tube passes. Enhancements to the airside surface area include increased fin pitch (decreased fin spacing), fin patterns (wavy or zigzag), and increased numbers of tube passes. 

Increasing the overall size of the coil in one or more dimensions without changing other 

aspects of the coil is another way to increase the area. However, most applications limit the 

amount of coil size increase. Most approaches to increasing the evaporator surface area also 

result in an increase in required fan motor power and an increase in refrigerant pressure drop. 

3.3.1.9 Low-Pressure Differential Evaporators 

Decreasing the air-side pressure drop of an evaporator coil allows for the use of lower 

power evaporator fan motors. This requires reducing restrictions to the flow of air across the coil 

such as high fin pitch and high numbers of tube passes. Large spaces between fins and tubes 

also reduce frost “bridging,” which can completely block airflow through portions of the coil. 

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3.3.1.10 Anti-Sweat Heater Controllers 

Anti-sweat heating controllers match the on-time of anti-sweat heaters to the anti-sweat 

heating requirements imposed by the ambient humidity, reducing energy consumption when 

ambient humidity is low. Anti-sweat heating is necessary to prevent moisture condensation on 

surfaces of display cases, the temperatures of which can be below the ambient dew point. 

Freezer-door gaskets are a typical example of such a surface. Anti-sweat heaters on 

freezer-door gaskets are typically always on, but the installation of controls that sense ambient 

humidity levels can turn off the heater when anti-sweat heating is not required, reducing 

electricity consumption. Such control requires measuring the local dew point or relative 

humidity, and measuring external surface temperatures. A particular heater can be turned on 

when the temperature of a particular surface falls below the dew point, or the heaters can be 

cycled with on-times increasing with dew point. Reducing anti-sweat heater on-time will also 

yield additional energy savings in display-case heat load reductions, since anti-sweat heaters 

contribute to case heat load. 

It is possible that electric anti-sweat heaters could be replaced by a hot gas line running 

around the doorframe. Although manufacturers have claimed that this is a difficult technology to 

implement, it has seen widespread and successful use in residential freezers. 

3.3.1.11 Improved or Thicker Insulation 

Either increasing the insulation thickness or reducing insulation conductivity will reduce 

the energy consumption of commercial refrigeration equipment. Typical insulation thickness for 

refrigerated display cases ranges from 11⁄2 to 2 inches. Blow-in polyurethane foam is used for 

most cases. The impact of an increase in insulation thickness and insulation quality is limited for 

open cases since a large portion of the cooling load is due to infiltration. 

Improved technology polyurethane foam insulation has reduced conductivity, reducing 

case heat load. The improvement is due mainly to the formation of smaller air cells within the 

foam insulation structure and better cell-size consistency. Use of the better foam would reduce 

display case wall load, assuming no wall thickness change. 

The importance of display case volume suggests that technologies that would allow 

reduction in insulation thickness while maintaining thermal resistivity (R-value) would be of 

interest. Vacuum panels could provide such performance. Vacuum panels are airtight panels 

sealed with glass or plastic, which are evacuated to eliminate a conduction path. They are 

generally filled with supporting powder that prevents collapse of the external seal. Much work 

needs to be done to demonstrate that vacuum panels will perform for many years without leaking 

and losing their insulating value. Additionally, existing vacuum panels do not provide the 

necessary structural rigidity between sheet metal panels that is possible with foamed-in-place 

polyurethane insulation.

3.3.1.12 Defrost Mechanism 

As the air in the refrigerated space is cooled, water vapor condenses on the surface of the 

evaporator coil. In refrigerators and freezers, where the evaporator coil is below 32°F, this water 

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freezes as it collects, forming a growing layer of frost. The frost reduces cooling performance by 

increasing the thermal resistance to heat transfer from the coil to the air, and by obstructing 

airflow. Both the method in which defrost is performed and control of the defrost cycle can lead 

to increased energy savings. 

There are several methods available for defrosting the evaporator coil: off-cycle defrost, 

electric defrost, and hot-gas defrost. Off-cycle defrost involves shutting off refrigerant flow to 

the coil while leaving the evaporator fan running. This method is used where case air is above 

the freezing point of water and can be used to melt the frost. Electric defrost is used when the air 

temperature is not high enough to defrost the coil, and when defrost must occur quickly to 

prevent any significant rise in product temperature. Electric defrost involves melting frost by 

briefly turning on an electric resistance heater that is in contact with or near the evaporator coil. 

Hot-gas defrost is only applicable to remote condensing systems and involves the use of 

the hot compressor discharge gas to warm the evaporator from the refrigerant side. Electricity 

usage is reduced in comparison to the electric defrost method because available heat, which 

would otherwise be rejected in the condenser, is used. The hot gas defrost system requires more 

complicated piping and control than electric defrost. An additional drawback is the thermal 

stress inflicted upon the refrigerant piping by the alternating flow of hot gas and cold refrigerant. 

3.3.1.13 Defrost Cycle Control 

Defrost-cycle control involves managing the initiation and termination of defrost cycles, 

and thereby the frequency and duration of defrost cycles. In the past, defrost cycles were 

completely scheduled, and initiation and termination were timer-controlled. Cycles were 

initiated at regular intervals and terminated after a fixed amount of time. Cycle frequency and 

duration were then unrelated to actual frost conditions. Under timer control, the frequency of 

defrost cycles is determined by the amount of time the manufacturer expects it to take for a large 

frost layer to develop in the worst-case scenario, and the cycle duration must be long enough to 

ensure complete defrost in the worst-case scenario. Timer-based defrost can lead to 

unnecessarily frequent and long defrost cycles. 

The current practice involves scheduled cycle initiation, determined by a timer, and 

demand-based cycle termination, determined by temperature sensors. Defrost cycles are still 

initiated at regular intervals, but are terminated when the coil temperature reaches a value 

indicating complete defrost. Partial demand-based defrost saves energy relative to fully 

scheduled defrost by limiting cycle duration, but cycle frequency can still be high. 

Fully demand-based defrost would eliminate unnecessary defrost cycles. Two methods 

currently exist for measuring demand-based defrost—measurement of cross-coil air-temperature 

drop and optical detection of frost buildup. Problems with these methods are associated with 

possible reduction of airflow due to dust collection, evaporator fan problems, varying product fill 

levels, and external flow disturbances. 

3.3.1.14 Thermoacoustic Refrigeration 

Thermoacoustic refrigeration uses high-amplitude sound waves in a pressurized gas to 

pump heat from one place to another. A device consisting of a series of small parallel channels, 

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referred to as a “stack,” is fixed in place at a set location inside a resonator tube. In the case of a 

thermoacoustic refrigerator, external work is supplied by the standing sound wave in the 

resonator. 

The longitudinal standing sound wave causes the gas particles to oscillate back and forth 

parallel to the walls of the stack. The alternating compression and rarefaction of the gas causes 

the local temperature of the gas to oscillate due to the adiabatic nature of sound waves. If the 

local temperature of the gas becomes higher than that of the nearby stack wall, heat is transferred 

from the gas to the stack wall. If the local temperature of the gas drops below that of the stack 

wall, heat is transferred from the wall to the gas. 

Prototypes of thermoacoustic refrigerators have been demonstrated for commercial 

refrigeration applications. A prototype thermoacoustic refrigeration unit designed for an icecream freezer has been measured to be as efficient as the vapor compression unit it replaces. 

DOE expects this technology to improve in efficiency with further development of heat 

exchangers and other subsystems. It is also likely that efficiency in many applications could 

improve because thermoacoustic refrigerators are well suited to proportional control, meaning 

that the cooling capacity can be continuously controlled so that the output can be adjusted 

accurately for varying load conditions. Although this technology currently does not improve the 

efficiencies of conventional refrigeration technology, thermoacoustic refrigeration has the 

environmental benefit of being refrigerant-free. 

3.3.1.15 Magnetic Refrigeration 

Magnetic refrigeration uses the magnetocaloric effect in which magnetocaloric materials 

like gadolinium absorb heat from their surroundings when entering a magnetic field, then reject 

heat to their surroundings when exiting a magnetic field. When magnetocaloric materials are 

circulated through magnetic fields and combined with heat exchangers to transfer heat, they can 

be used to remove heat from a refrigerated space and reject heat to the surroundings. 

This refrigeration technology could be used in any possible application where cooling, 

heating, or power generation is used today. Because of the early stage of development, however, 

many technical issues need to be addressed for this technology to be commercially viable. 

3.3.1.16 Electro-Hydrodynamic Enhanced Heat Transfer 

Electro-hydrodynamic (EHD) enhanced heat transfer is the result of applying a highvoltage electrostatic potential field across a heat transfer fluid, such as a refrigerant or refrigerant 

mixture. The applied field destabilizes the thermal boundary layer, thereby producing better 

mixing of the bulk fluid flow and increasing the net heat transfer coefficient. This procedure 

appears to be more effective when applied to phase-change processes (e.g., boiling and 

condensation). 

 This phenomenon is typically used to electronically control the capacity of a heat 

exchanger by raising the applied voltage to increase the heat transfer. This can lead to improved 

efficiencies by using smaller capacity equipment, most of the time without EHD, and then using 

the EHD effect during peak loads. EHD can replace, or work in conjunction with, enhanced 

surface heat exchangers. To use EHD, an electrical voltage (from a few volts to thousands of 

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volts) is applied to the heat transfer device. However, because the heat transfer fluids are 

typically dielectric (of low electrical conductivity), even high voltages produce very little 

current. This low current helps keep the power (voltage x current) and the associated energy 

penalty low. 

3.3.1.17 Copper Rotor Motors 

Making the critical components of an induction motor's rotor (e.g., conductor bars and 

end rings) out of copper instead of aluminum, which is the common current practice, improves 

the motor’s energy efficiency. The greater conductivity of copper results in lower resistance 

heating losses in the rotor and thus lower losses in the motor. Improvements in the design and 

fabrication of copper motors, such as optimization of the steel laminations, could further increase 

the efficiency of copper motors over aluminum motors. 

3.3.2 Designs Relevant Only to Equipment without Doors 

The air-curtain design option is relevant only to equipment without doors. 

3.3.2.1 Air-Curtain Design 

Refrigerated display cases without doors allow consumers easy access to products while 

maintaining temperatures that ensure food safety. The absence of doors necessitates the use of a 

circulated air curtain to keep cold air inside the case. The refrigeration load for these cases is 

dominated by infiltration, or the entrainment of warm and moist air into the curtain. This 

infiltration adds both sensible and latent heat to the case, and deposits additional moisture on the 

evaporator coil, which must be removed through defrosting. 

Improved air-curtain design is aimed at lessening the impact of infiltration by reducing 

the entrainment of warm ambient air. Making the air curtain flow as laminar as possible reduces 

entrainment. This involves configuring the plenum before the air curtain discharge grill to shape 

the velocity profile using a honeycomb grill to align the airstreams and encourage laminar flow. 

Improvements to the velocity profile and discharge air grill may enhance the performance of the 

air curtain and reduce the infiltration load. 

3.3.3 Technologies and Designs Relevant Only to Self-Contained Equipment 

The following technologies and designs are relevant only to self-contained equipment: 

higher efficiency compressors, liquid suction heat exchangers, increased condenser surface area, 

higher efficiency condenser fan motors, condenser fan motor controllers, and higher efficiency 

condenser fan blades. 

3.3.3.1 Higher Efficiency Compressors 

Several technologies exist to increase the efficiency of commercial refrigeration 

equipment compressors. High-efficiency reciprocating and scroll compressors, sometimes 

incorporating variable-speed motors, all have higher efficiencies than the traditional 

reciprocating compressors commonly used in commercial refrigeration equipment. 

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Scroll compressors compress gas between two spirals, one fixed and one rotating. This 

method is fundamentally different from that of traditional compressors. High-efficiency 

reciprocating compressors are as efficient, or more efficient, than scroll compressors. However, 

when compared to scroll compressors, some drawbacks exist, including noise, cost, and 

reliability. 

Variable-speed compressors are implemented through an electronic control on the 

compressor motor, which allows the motor to operate at different speeds. Variable-speed 

compressors reduce energy consumption in three ways:h

1. When refrigerant flow is reduced during part-load operation, the condenser and 

evaporator (designed for full flow conditions) are more effective and thus more 

efficient. Temperature drops decrease, resulting in reduced pressure rise across the 

compressor, which also improves efficiency. 

2. Close matching of load eliminates the cycling that occurs with single-stage 

compressors. Maintaining a constant pressure is more efficient because losses at 

higher pressure rise are greater than gains at lower pressure rise. 

3. During the off cycle, the pressure in the system equilibrates. At intermediate 

pressure, refrigerant vapor will condense in the cold evaporator rather than the 

condenser. Essentially, some of the heat rejection load is rejected to the evaporator 

during this time, reducing overall system performance. Variable-speed operation 

would eliminate or significantly reduce compressor off-time and the related 

inefficiencies. 

3.3.3.2 Liquid Suction Heat Exchangers 

The goal of a liquid suction heat exchanger is to further cool the flow of liquid refrigerant 

entering the expansion valve using the flow of gaseous refrigerant leaving the evaporator. The 

exchanger provides sub-cooling for the entering liquid by super-heating the exiting suction 

vapor. Hotter suction vapor is less susceptible to heat gains in the return piping to the 

compressor rack. The compressor work is increased, however, because the suction vapor has 

greater enthalpy. In addition, the possibility of compressor overheating problems brought on by 

the combination of increased compressor work and hotter vapor limits the use of this method in 

some situations. The possibility for these problems and the potential efficiency gains from liquid 

suction heat exchangers depend on several factors, including evaporator temperature, type of 

refrigerant used, and system pressures. 

3.3.3.3 Increased Condenser Surface Area 

Like the evaporator, the condenser is a refrigerant-to-air heat exchanger composed of 

metals with high thermal conductivity such as aluminum and copper. It is responsible for 

condensing and sub-cooling the entering refrigerant vapor while rejecting heat from the 

refrigerant to the ambient air. 

 

h

 Variable-speed compressors typically increase efficiency over a broad operating range but do not inherently 

increase maximum efficiency at the compressor rating point 

 EE-2006-STD-0126 COMMENT 23.2
3-38

Depending on the requirements of the equipment, the condenser’s saturated condenser 

temperature (SCT) is about 10°F warmer than the ambient air. As with evaporator coils, 

increasing the area of the condenser coil will decrease the necessary ∆T across the coil and 

therefore decrease the SCT, resulting in increased compressor efficiency (and thus increased 

EER). 

Enhancements to the refrigerant-side surface area of the condenser typically include 

rifled or diamond-pattern tubing and increasing the number of tube passes. Enhancements to the 

air-side surface area include increased fin pitch (decreased fin spacing), fin patterns (wavy or 

zig-zag), and increased numbers of tube passes. 

Increasing the overall size of the coil in one or more dimensions without changing other 

aspects of the coil is another way to increase the area. However, most applications limit the 

amount of coil size increase in order to maintain overall equipment dimensions. Most 

approaches to increasing the condenser surface area also result in an increase in required fan 

motor power and an increase in refrigerant pressure drop. 

3.3.3.4 Higher Efficiency Condenser Fan Motors 

Condenser fan motors are responsible for moving air across the condenser coil and 

typically run at one speed. The manufacturer will match the motor size and blade to the 

evaporator coil to meet the expected load on the case under most conditions. Higher efficiency 

condenser fan motors reduce energy consumption by requiring less electrical power to generate 

motor shaft output power. Condenser fan motors are generally of the same size and type as 

evaporator fan motors. See section 3.3.1.5 for a discussion of higher efficiency fan motor 

technology. 

3.3.3.5 Condenser Fan Motor Controllers 

Condenser fan motor controllers allow fan motors to run at variable speed to match 

changing conditions in the case. Matching the fan speed to all conditions improves coil 

performance. This allows the refrigeration system to run more efficiently at different ambient 

humidity and temperature levels. However, under steady-state conditions, there is no energy 

savings benefit with condenser fan motor controllers. 

3.3.3.6 Higher Efficiency Condenser Fan Blades 

High-efficiency condenser fan blades, or tangential condenser fans, move air more 

efficiently, yielding energy consumption savings by reducing the required fan shaft power. The 

condenser fans typically used in commercial refrigeration equipment have sheet metal blades. 

Usually, a fan blade manufacturer supplies the blades and the equipment manufacturer mounts 

them to the motor. These fan blades are not optimized for commercial refrigeration equipment. 

Required fan shaft power could be reduced if the fan blades were optimized for each application. 

Tangential fans also provide an opportunity to decrease CRE energy consumption. These 

fans use a vortex builder to generate a uniform airflow over a large surface. This makes them 

ideal for evaporator and condenser fans that need to distribute airflow over a large surface area. 

 EE-2006-STD-0126 COMMENT 23.2
3-39

A single long tangential fan can meet the airflow requirements for an entire condenser, and 

require only one high-efficiency fan motor.

 EE-2006-STD-0126 COMMENT 23.2
3-40

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