When a company is one of the largest beverage distributors in the U.S., it’s crucial to stay ahead of the curve on everything that drives customer satisfaction, corporate responsibility, and a strong bottom line.
Hensley Beverage Company did exactly that when it collaborated with Chemours and American Refrigeration Supplies, Inc. (ARS) to implement a system utilizing a new-generation A2L refrigerant, Chemours Opteon™ XL20 (R-454C).
Completed in 2023, the installation paves the way for companies throughout the commercial refrigeration industry to embrace refrigerant technologies that are both cost-effective and environmentally sustainable.
Situation
Hensley Beverage, a Phoenix-based beverage wholesaler, supports a customer base of more than 9,000 accounts and more than 2,500 individual products, operating out of six locations across Arizona, USA.
Hensley remains committed to maintaining exceptional product integrity, upholding its business legacy
The company recently completed an acquisition that expanded its distribution footprint into New Mexico, making it one of the nation's largest family-owned and operated beverage distributors.
As it grows, Hensley remains committed to maintaining exceptional product integrity, upholding its multi-generational family business legacy, and supporting various environmental objectives.
Upgrading refrigeration systems
These factors, coupled with the current regulatory landscape (notably, the phasedown of legacy hydrofluorocarbon (HFC) refrigerants), have put Hensley’s focus on ways to upgrade its refrigeration systems.
For the past several years, Chemours, ARS, and Hensley have worked together to retrofit the distributor’s existing R-22 and R-404A systems to Opteon™ XP40 (R-449A), a hydrofluoroolefin (HFO) blend offering zero ozone depletion potential (ODP) and a significantly lower global warming potential (GWP) than legacy products.
Phasedown of HFC refrigerants
Hensley Beverage is proud to partner with Chemours, TBSI, and ARS to help develop innovative solutions"
However, with the ongoing phasedown of HFC refrigerants under the U.S. EPA’s American Innovation and Manufacturing Act (AIM), the teams began weighing the benefits of an even bolder upgrade.
“Hensley Beverage is proud to partner with Chemours, TBSI, and ARS to help develop innovative solutions and responsible business practices that drive sustainability in our community," said Alex Dunn, SVP of Operations, Hensley Beverage.
Partnership and collaboration
Alex Dunn adds, "These groundbreaking results are a culmination of partnership and collaboration. It is refreshing to work with three organizations that are this passionate about developing pioneering products that will help shape a better future for the communities we serve.”
Solution
A mildly flammable refrigerant with an ASHRAE A2L safety classification, Opteon™ XL20 is designed for use in new equipment
Even as Chemours, ARS, and Hensley continued to employ retrofit solutions in some areas strategically, they explored options that would put the company in a stronger position for the long term.
Chemours recommended bringing Opteon™ XL20 (R-454C) into Hensley’s refrigeration plan. A mildly flammable refrigerant with an ASHRAE A2L safety classification, Opteon™ XL20 is designed for use in new equipment, so Hensley identified an old R-22 system near the end of its life that was ideal for replacement by a new system using Opteon™.
Opteon™ XL20
Opteon™ XL20 has been used for several years in Europe and is expected to become the new norm in the U.S. by 2026, based on the current direction provided by the EPA.
Leveraging its experience in Europe, the Chemours team of technical service and business development resources is prepared to support end users as they consider trial installations using A2L refrigerants.
Opteon™ XL20 - The future of sustainable low- and medium-temperature refrigeration:
- GWP of 148 (a 96% reduction versus R-404A).
- Zero ODP.
- Enables much higher charge sizes than highly flammable A3 refrigerants.
- Is a close performance match to R-22 and R-404A.
- Offers the optimum balance of performance and environmental sustainability.
- Provides an easy, cost-effective alternative to legacy refrigerants and new equipment applications.
- Utilizes well-known technology for ease of service and maintenance.
performance, efficiency, and sustainability
“Hensley was an early adopter of Opteon™ XP40, retrofitting equipment to experience better environmental outcomes, as well as high performance in low- and medium-temperature applications. Experiencing these benefits of HFOs whet their appetite to ask, ‘What next?’," said Joe Martinko, President of Thermal and Specialized Solutions, Chemours.
Joe Martinko adds, "With a strong dedication to supporting their communities and the environment, while operating an efficient and thriving business, Hensley is a company that pushes the envelope. Chemours was ready with our next-generationOpteon™ XL20, which will ensure they achieve maximum performance, operating efficiency, and sustainability."
servicing and Installation
Heatcraft and Copeland had the knowledge and experience of emerging A2L requirements
The installation brought together additional resources from the HVACR industry, including Copeland and Heatcraft Refrigeration Products, two ARS manufacturing partners as well as Technical Building Services, Inc. (TBSI), the local HVAC service provider.
As global HVACR technology pioneers helping customers achieve their sustainability, decarbonization, and regulatory compliance goals, Heatcraft and Copeland had the knowledge and experience of emerging A2L requirements and the capabilities to support the project. TBSI was selected as the contractor for installation and servicing.
Time- and cost-efficient
With the team assembled, Chemours took the head on the project, ensuring that the contractor, Hensley’s service personnel, and others involved were certified through the ESCO Institute’s A2L refrigerant training program, and answering any questions from the local authorities.
After safely recovering the R-22 for use in other Hensley systems, the team from TBSI started removing the existing Keg 6 equipment, hanging new evaporator coils, and running new refrigerant lines. Installation, evacuation, and charging procedures were very similar to the current refrigerants in use by industry, making for a time- and cost-efficient process.
Climate technology
Copeland has always been focused on not just setting the standard in climate solutions"
“Copeland has always been focused on not just setting the standard in climate solutions with pioneering brands in compression, controls, software, and monitoring, but pioneering the evolution in this space. Our role in the system design and installation for Hensley was right in our wheelhouse," said Brian Schroeder, Engineering Manager, Refrigerants, Copeland.
Brian Schroeder adds, "What we accomplished together demonstrates that by bringing together energy-efficient products,regulation-ready solutions, and expertise, we can revolutionize the next generation of climate technology for the better.”
R-454C refrigerant
“Our tools and gauges were already enabled for the R-454C refrigerant. The startup and charging of both systems went pretty smoothly," said Sergio Pelayo, Vice President of TBSI.
Sergio Pelayo adds, "TBSI is proud to have participated in the project at Hensley and, by doing so, added to the variety of equipment we’ve worked on since founding our business in 1990. This was a great opportunity to grow our experience with A2Ls.”
Copeland monitoring data
Copeland applied monitoring units to the systems that capture nearly two dozen data points every second
To make sure the system performed as expected, Copeland applied monitoring units to the systems that capture nearly two dozen data points every second. The data has shown that the systems are running as designed.
“We are thrilled with the results of the R-454C project with Hensley Beverage," said Bob Landi, Vice President and General Manager of Heatcraft Refrigeration Products.
Bob Landi adds, "As we continue our journey toward new regulation compliance, this successful collaboration has been instrumental in leveraging Heatcraft’s new product design efforts, with A2L refrigerants being an important part of the mix. We are poised to head the industry and provide more customers like Hensley with cutting-edge solutions that drive their success.”
Summary
Influenced by upcoming regulatory changes and stronger organizational ESG commitments, the commercial refrigeration industry’s transition to lower GWP refrigerants is inevitable.
Opteon™ refrigerants provide organizations with lower GWP options that can help extend the useful life of their systems, as well as new equipment options that enable decades of reliable operation. Moreover, these systems answer the consumer preference for businesses that utilize responsibly manufactured products and support a greener environment.
Hensley’s approach
Hensley’s approach demonstrates an ideal way for companies to meet the needs of refrigerating their products while following the guidelines of the HFC phasedown.
It’s important to assess where equipment is in its lifecycle and determine if it makes the most sense in terms of budget, performance needs, and corporate vision to 1) retrofit existing equipment for more efficient and sustainable operation or 2) replace it with A2L refrigerant technologies and products.
