By Eamonn Ryan
At FRIGAIR 2025, mechanical engineer Thiago Fernandes who at that time was from Full Gauge Controls presented insights into two refrigeration technologies: adiabatic condensation and floating condensation.
His message was that when applied correctly, these innovations can significantly improve efficiency, reduce environmental impact and cut operational costs.
“Adiabatic condensation can increase efficiency by up to 30% compared to traditional dry cooling,” said Fernandes. “And floating condensation can offer energy savings of around 15% by allowing systems to adapt to changing outdoor temperatures.” These gains, he explained, are especially valuable in industries like food processing, pharmaceuticals and chemical manufacturing, where refrigeration reliability and efficiency are critical.
Adiabatic condensation uses evaporative cooling to pre-cool the air before it enters a heat exchanger. “You spray or pass water through pads to lower the air temperature, which makes the condenser work more efficiently. This process helps reduce the condensing pressure, lowering the workload on the compressor and, in turn, reducing energy use,” Fernandes said.
Dry cooling, by contrast, relies solely on ambient air and uses no water. It’s well- suited to water-scarce regions but doesn’t offer the same efficiency boost. “With adiabatic systems you only use water when needed—typically during high ambient temperatures—which makes it a smart, cost- effective choice for improving performance without excessive water use.”
Different adiabatic configurations are available, including spray systems, pad systems and hybrid designs. These systems can either discard or recirculate the water, depending on environmental and maintenance considerations. “Recirculated water systems need some treatment, but they can minimise waste and scale buildup, making them more sustainable over time,” he noted.
Floating condensation is another key energy-saving strategy. Rather than operating the condenser at a fixed pressure, the system adapts based on ambient outdoor temperatures.
“In cooler weather, there’s no need to maintain high condensing pressures,” Fernandes explained. “If the outside air is colder, the compressor can operate at a lower pressure, reducing its workload.” This dynamic approach improves the coefficient of performance (COP) – a measure of how efficiently a system uses energy – and helps extend compressor life due to reduced mechanical stress.
Fernandes noted that this method can reduce compressor power consumption by 10–20%, lower fan speeds (further saving energy), and even cut refrigerant losses due to decreased system pressure.
million tonnes.
The power of combining both
“These two technologies are not mutually exclusive. Using adiabatic cooling and floating condensation together offers even greater energy savings, especially in air-cooled systems,” Fernandes said. The combined effect lowers both energy use and mechanical wear, improving system uptime and reducing maintenance needs.
Crucially, lower system pressure also means less stress on piping and a reduced risk of refrigerant leakage – an important consideration as refrigerants become more costly and environmentally regulated.
Industries already using these technologies include food production pharmaceuticals and chemicals – sectors where energy use is high and reliability is non-negotiable.
To demonstrate the impact, Fernandes pointed to comparative analyses. “When we measure energy efficiency ratios and system reliability before and after implementing these methods, we see clear, quantifiable improvements,” he said. Some users report up to 30% reductions in energy use, significantly lowering their operational costs.
And for those concerned about water consumption, Fernandes offered a practical view. “The return on investment really depends on your location,” he said in response to an audience question. “In water-scarce areas, you might use recirculated systems, where water usage is minimal. In other places, the energy savings far outweigh the cost of water. The key is choosing the right system for your conditions.”
Fernandes pointed to future trends in refrigeration, noting that automation and real-time monitoring are becoming essential. “You can’t optimise what you don’t measure. With modern controllers and software, you can track performance, identify issues early and fine-tune operations for maximum efficiency.”
Systems from Full Gauge Controls, for example, allow users to monitor energy use, pressure and temperatures remotely – ensuring systems operate at peak performance while enabling proactive maintenance.
“Adiabatic and floating condensation are not just engineering tweaks. They are strategic upgrades that align with sustainability goals and financial performance. These systems reduce emissions, extend equipment lifespan and offer a strong return on investment.”
For businesses looking to modernise their refrigeration systems, Fernandes’ message is simple: start with the data, choose the right technology for your environment, and monitor continuously. The savings – financial and environmental – are real.