Compiled by Eamonn Ryan with technical input from Nigel Pengelly, managing member of VMG Consultants, and Frikkie Kleyns, technical manager at Elmec Airconditioning
With the objective of using less energy and reducing unnecessary waste, VMG Consultants is assisting Pick n Pay to refurbish its air conditioning systems across multiple stores with energy-efficient technology while keeping over 15 tonnes of waste from landfill.
For instance, during the 2020 renovation of Pick n Pay On Nicol, the retailer benefited from the significant environmental perk of refurbishing air handling units (AHUs) instead of replacing them. Nigel Pengelly, managing member of VMG Consultants says that to date, 14 stores have had their AHUs refurbished, with another 17 in the pipeline.
This includes refurbishing water-cooled packaged units to air-cooled ones, focusing on the waste hierarchy of reducing and reusing to improve sustainability. Each refurbishment keeps about half a tonne of polystyrene – which isn’t recyclable – from landfill, sparking a wider rollout of the strategy.
“Existing equipment, which is 20 years old but essentially relies on technology which is over 40 years old and therefore was designed and installed using energy-inefficient technology – because there were no alternatives. Today, I ask landlords ‘Would you drive a 45-year-old car, just because it still works?’. By using new technology such as computer-aided design and sophisticated computer programs, today we can optimise a supermarket’s air-conditioning units and reduce the size and running costs of equipment required that are 30-60% more efficient,” says Pengelly. VMG has been working with Pick n Pay for 40 years, he says, and has built a strong trusted relationship.
In one refurbishment project, Pengelly notes that a like-for-like replacement would have cost Pick n Pay’s landlord around R13 million, compared to a refurbishment cost of R8.5 million for the air-conditioning. “There are huge savings to be made if you do it right.”
Pengelly, who has been integral to the refurbishment project, highlights the significant advantages of working with LG’s state-of-the-art controls. “LG, along with other major manufacturers, now offers comprehensive control solutions for their equipment. This ‘one-stop-shop’ approach simplifies relatively complex control logic and ensures seamless compatibility with their highly technical equipment.”
LG’s innovation extends beyond traditional air conditioning units. Its Smart 5 Controller, paired with an associated I/O (input/output) module, represents a leap forward in its control technology. This system provides complete control over all HVAC components, and not limited to LG’s own equipment. “What sets LG apart is its high-quality ‘built-in’ control-programmes and ease of programming for the end-user. Unlike outsourcing alternative controls where software development might be tedious and fraught with time-consuming problems, LG’s controllers are supported by an inhouse team that produces tried and tested well-designed programs, which are constantly being improved and updated at no additional cost. This means you get advanced features without the need for extensive customised programming and expensive upgrades.”
The ease of on-site programming LG systems is another key benefit. The Smart 5 Controller’s interface is designed to be accessible even to those without a background in computer science. Pengelly praised the system for its intuitive design, which eliminates the need for expensive and complex custom software solutions.
This technological advancement aligns perfectly with Pick n Pay’s sustainability goals. By upgrading to these advanced LG systems, the retailer not only improves energy efficiency but also reduces operational costs and environmental impact.
Pengelly, who has been working with Pick n Pay for 35 years, comments on the retailer’s commitment to innovation and sustainability. “Previously, Pick n Pay’s fresh air systems were set manually
and locked in place based on the maximum possible population density. By implementing CO₂ sensors, we’ve introduced a dynamic, responsive system that adjusts fresh air supply based on the actual store occupancy throughout the day.”
One of the most impressive features of LG’s technology is its connectivity. The Smart 5 Controller can be monitored and adjusted remotely via a modem, allowing real-time control from anywhere in the world. “We can make adjustments from our office or even a smartphone, no matter where the store is located. This level of remote control and programmability is a game-changer for maintaining and optimising air conditioning systems efficiently.”
In addition to advanced controls, Pengelly has also recommended installation of other innovative equipment options, such as VRF chillers. These chillers, which use inverter technology to modulate performance rather than simple on/off cycling, offer increased efficiency and reliability. “VRF chillers are a great example of how modern technology can enhance our systems. They provide precise control and are much more efficient compared to traditional chillers.”
The integration of plug fans and other components from various suppliers, including HC Aircon and Ziehl Abegg, further complements the system’s efficiency. By VMG sourcing these components in bulk, Pick n Pay benefits from cost savings while ensuring high-quality performance. The company also obtained a 10-year warranty on compressors from many reputable manufacturers due to their high standards of maintenance.
“The beauty of plug fans lies in their ability to provide exact air quantities with ease. Unlike traditional belt-driven centrifugal fans, which often require cumbersome adjustments to pulleys and belts, plug fans allow for straightforward tuning. This capability ensures that we can achieve the exact air flows we require and corresponding energy savings.”
Plug fans are particularly effective because their power consumption drops significantly as air flow is reduced. “When we decrease the air flow by a small margin, the power consumption decreases significantly. This results in substantial energy savings, which is crucial for maintaining operational efficiency and reducing costs,” Pengelly explains.
Additionally, the advent of computer programs and advanced design tools has transformed the approach to air conditioning system design and replacement. In the past, systems were designed manually with rudimentary tools, leading to inefficiencies. “Forty years ago, system design relied on manual calculations and estimates. Even now, old systems are simply replaced on a ‘like-for-like’ basis with no consideration given that the original systems could well have been over-designed. This practice has persisted despite the availability of computer programmes and later, more sophisticated tools.”
Today, the industry benefits not just from highly advanced computer programs but artificial intelligence, yet some practices remain outdated. “The use of advanced design tools should be standard practice, not optional. We have access to powerful software that can perform detailed heat load analyses and optimise system design”.
Revamping air conditioning units is an ongoing process that requires a meticulous and critical approach. Pengelly explains that the key to successful refurbishment lies in evaluating whether a unit can be effectively upgraded or if it should be replaced entirely. This assessment often involves a thorough review of the existing equipment, considering both the potential benefits and limitations of refurbishment.
Effective refurbishment often hinges on the ability to work closely with contractors and suppliers. For instance, when faced with urgent timelines, it’s crucial to coordinate with manufacturers to expedite the process. An example of this was one Pick n Pay refurbishment project where new equipment was needed urgently. By collaborating with the manufacturer and emphasising the urgency, the team managed to get a new unit built in just six weeks, despite the usual 12-week lead time.
In environments like supermarkets, where operational continuity is critical, the challenge is to complete refurbishments as quickly as possible, without disrupting daily operations. “It’s essential to plan refurbishments in stages, ensuring that air conditioning systems remain functional for as long as possible throughout the process. More peripheral work, such as painting and lighting, can be deferred in order to accelerate the installation and commissioning of the critical equipment”.
Refurbishment typically involves integrating new parts and technology to enhance performance. For instance, HC Aircon and Zeihl Abegg provide new components such as coils and plug fans, which are crucial for modernising older units. These components often offer better efficiency and reliability compared to the original parts.
“Refurbishing a unit is not a one-size-fits-all solution. It requires an engineering assessment to determine if refurbishment is feasible and cost-effective. Factors such as the age of the equipment and the condition of the existing structure must be carefully considered. The decision to refurbish is based on a thorough inspection of the existing unit. Only a relatively small proportion of units are considered suitable for refurbishment.
“By integrating modern components and utilising advanced technologies, refurbishment can extend the lifespan of older units while enhancing their efficiency. Effective refurbishment also requires a thorough understanding of engineering principles and cost considerations, ensuring that decisions are based on a comprehensive evaluation of the equipment’s condition and potential benefits.
“Refurbishment is a complex process that benefits from experience and expertise. By adopting a methodical approach and leveraging modern technologies, it’s possible to achieve significant improvements in performance as well as significant cost savings, while maintaining operational continuity,” adds Pengelly.
Elmec Airconditioning’s role in the Pick n Pay refurbishing project
Frikkie Kleyn, managing member at Elmec Airconditioning, discusses the company’s pivotal role in the refurbishment of various Pick n Pay stores nationwide.
Kleyn emphasises the significant improvements made in the refurbishment timeline, reducing downtime from 12-16 weeks to just 5-8 weeks. “The key focus is on minimising disruption to daily operations while ensuring quality work,” he notes. This shift not only saves costs but also enhances the shopping experience for customers.
Elmec’s refurbishment process involves thorough inspections of existing air conditioning units to assess their viability for refurbishment. “We have extensive experience refurbishing these systems. If a unit isn’t likely to last another 15 to 20 years, it doesn’t make sense to refurbish it.”
The refurbishment strategy includes complete overhauls of the air conditioning units. “We essentially strip everything down to the shell. Then, we replace all internal components, including wiring, coils and fans, ensuring everything looks brand new. The goal is for the client to feel like they’ve installed a new system, even if the outer shell is the original unit.”
He cites one of his greatest compliments received, which ironically was initially meant as a criticism: “The project owner’s national operations manager queried why there were a couple of small dents on what he assumed was a new box. He couldn’t believe it when I clarified that it was a refurbished 20-year-old box. Once he realised the context, he doubly appreciated the work we had done.”
Kleyn also shares that the feedback from Pick n Pay has been overwhelmingly positive. “Nigel has been instrumental in this project, and the responses from him and his team reflect our commitment to quality and performance,” he says. The focus on achieving the best possible outcomes for Pick n Pay balances innovation with practicality. “We want our work to not only meet expectations but exceed them.”
According to Kleyn, the refurbishment aims to address multiple concerns, primarily focusing on cost savings, environmental sustainability and operational efficiency. “One of the main reasons for refurbishing the air conditioning systems is to provide significant cost savings compared to replacing the entire unit,” he explains. By refurbishing, they aim to retain some components, effectively ‘recycling’ materials rather than simply discarding them.
When asked how Elmec ensures that refurbishments do not interfere with Pick n Pay’s daily operations, Kleyn highlights the preparation phase. “A significant portion of the work can be done while the existing systems are still operational,” he says. Most units they encounter are already partially failed, allowing Elmec to start preliminary work without affecting store performance.
“By using the available space in plant areas, we can install new condensing units and complete much of the pipework in advance. This way, by the time the new coils arrive, we’ve already done about 50% of the work.”
In cases where complete shutdowns are necessary, like during peak summer, Elmec strategically plans the refurbishments to minimise impact. “We ensure that we do most of the heavy lifting during off-peak hours, often in the evenings,” he explains. This careful scheduling allows for seamless transitions with minimal downtime.
Kleyn also discusses the innovative LG Smart 5 controller, which enhances the functionality of the refurbished systems. “This is a versatile controller that simplifies programming and allows for real-time monitoring,” he says. The tablet-shaped device is easily integrated into the existing infrastructure, allowing technicians to manage and program the system without requiring specialised software skills.
The use of the LG Smart 5 controller allows for remote monitoring, further enhancing the efficiency of the refurbished systems. Kleyn highlights this technology as a crucial element in maintaining operational standards while meeting modern environmental criteria.
The LG Smart 5 controller supports various inputs and outputs, providing flexibility and comprehensive oversight of the refrigeration system. “It enables us to monitor crucial parameters like refrigeration pressures and system data.” This capability allows Elmec’s technical team to diagnose issues remotely before dispatching technicians to the site.
“This off-site monitoring is a game-changer as a standard feature without the addition of expensive building management systems (BMS). Unlike traditional systems where you can only check if a unit is on or off, the LG Smart 5 gives us detailed insights into system performance. This means we can address potential issues proactively, ensuring efficient operations for Pick n Pay.”
Coordination is vital in such a project. “VMG takes the lead on project management. They handle the design aspect and oversee the overall quality throughout the project. My role focuses on the installation and communication with suppliers and manufacturers, ensuring everything runs smoothly.”
This structured collaboration allows for a seamless workflow, with VMG managing project timelines and quality checks while Elmec concentrates on the technical aspects and installations.
Commitment to quality work
VMG uses Elmec primarily because the quality of its workmanship exceeds that of other contractors. “I think it comes down to passion. I genuinely enjoy what I do, and that passion drives me to deliver the best results.” He recalls lessons from his father about the joy of creating something beautiful from nothing, which he applies to every refurbishment project.
“I’ve always had a knack for taking old items and revitalising them,” says Kleyn. “When Nigel approached me about this work a few years ago, I was excited to give it a shot. Since then, I’ve thoroughly enjoyed transforming these systems.”
Kleyn describes each refurbishment as unique, emphasizing that no two projects are the same. “Every plant, every situation, every location presents different challenges and opportunities. I take pride in making each refurbished unit stand out, and it’s rewarding to see the reactions of clients when they walk into a space and see the improvements.
“If I can achieve a sense of satisfaction from our clients, then I know I’ve done my part.”