By Eamonn Ryan
Refrigerants, thermal storage and backup strategy in industrial heat pumps.
Freepik.com
As highlighted in Apple podcast From The Cold Corner platform conversation between Michael Levitt of Refrigerated & Frozen Foods and Marc Gieseking of Güntner, the success of an industrial heat pump project depends not only on installation – but on integration.
Industrial heat pumps must work in harmony with refrigeration systems, process heating loads and reliability planning.
Integrated heating and cooling systems in food processing
In food production environments, heating and cooling are interdependent.
Breweries, dairies, meat processors and frozen food manufacturers generate significant waste heat during refrigeration and processing. Rather than rejecting this energy through dry coolers, facilities can redirect it into an industrial heat pump.
The system upgrades low-grade waste heat into usable hot water for:
- Cleaning-in-place systems
- Sanitation processes
- Process heating
- Space heating
Properly engineered integrated heating and cooling systems reduce boiler dependency and significantly improve overall plant efficiency.
But integration requires co-ordination across:
- Refrigeration loops
- Heat exchangers
- Process water systems
- Controls and automation
This is multidisciplinary engineering – not a standalone equipment decision.
Natural refrigerants in heat pumps: CO₂ and ammonia
Refrigerant selection is a strategic decision in industrial heat pump projects.
Natural refrigerants in heat pumps – particularly CO₂ and ammonia – are increasingly favoured due to their low or negligible global warming potential.
Ammonia remains dominant in very large systems due to its thermodynamic efficiency and scalability. Industrial CO₂ heat pump installations have also expanded significantly with some exceeding 15MW.
However, refrigerant selection must align with:
- Target output temperature
- System capacity
- Local regulatory frameworks
- Safety requirements
- Available technical expertise
There is no universal solution. Comparative engineering analysis is essential.
Thermal storage and backup systems for industrial heating
Food production facilities cannot tolerate downtime.
For this reason, backup systems for industrial heating remain essential even when industrial heat pumps are installed.
Facilities may include:
- Backup gas boilers
- Emergency cooling systems
- Thermal storage in food processing plants
- Ice storage systems
- Large hot water buffer tanks
Thermal storage can bridge maintenance windows or short-term outages, enhancing resilience. Industrial heat pumps strengthen energy security – but they do not eliminate the need for redundancy.
Long-term success requires early collaboration
Across heat source selection, integrated system design, refrigerant strategy and backup planning, one theme remains consistent: start early.
Industrial heat pump projects often span months or years from feasibility to commissioning. The most successful installations begin with clear objectives, cross-disciplinary collaboration and realistic timelines.
Industrial heat pumps are not accessories. They are foundational infrastructure.
For cold chain operators, decarbonised heating depends on thoughtful system integration, strategic refrigerant choice and comprehensive reliability planning.