While there are some challenges currently facing the industry, the future is bright. Products that support system efficiency and improve manufacturing and maintenance support are setting the stage for long-term success.  

Barriers to Adoption 

Despite the seemingly inevitable adoption of CO₂ refrigeration in the U.S., there are still challenges that stand in the way. However, the benefits are clear. From an environmental perspective, according to a 2023 Forbes article, traditional HFCs are 10,000 times more damaging to the ozone layer than CO₂, pointing to CO₂ as a clearly superior option for environmental impact. In addition, European adoption and experience have proven the reliability and long-term viability of CO₂ systems. 

And yet there are hurdles -- one of them being the supply chain support of CO₂ systems. Across the industry, as even some of the largest grocery chains in America are looking to make large commitments to CO₂ refrigeration, they aren’t able to get all the racks they need to make full transitions.  

Along with the manufacturing gap comes the lack of trained professionals to install and maintain these systems. While the number of trained technicians and contractors is growing, there is still a great opportunity for contractors to get familiar with and trained on CO₂ systems. This one-two punch of infrastructure is common in an industry shift such as this, and it will be overcome -- as we’ve seen in Europe -- but it has certainly slowed the adoption of CO₂ refrigeration in the U.S. 

Another consideration is the energy-intensive nature of CO₂ refrigeration in warm climates and the upfront capital cost of switching systems. While it’s better for the environment overall, CO₂ refrigeration can cost more to operate in areas with high ambient temperature weather. Not to mention, the capital expense of changing any refrigeration system is significant. While retailers are transitioning to CO₂ refrigeration to improve their environmental impact -- whether due to sustainability commitments or government regulations -- they’re also looking to lower operating costs where possible. 

Weighing the Benefits 

To help make CO₂ systems run more efficiently and curb operating costs, one solution is to pair a CO₂ system with an energy recovery device, such as a pressure exchanger. The pressure exchanger improves the efficiency of a CO₂ refrigeration system by recovering the high-pressure energy from the exit of the gas cooler that would have otherwise been wasted. It can be incorporated into new or existing systems to reduce energy, increase capacity, and decrease water usage and maintenance costs, potentially lowering costs long-term and improving performance in the long run, even with the upfront capital expense. 

SIGNIFICANT INVESTMENT: The switch to CO2 for many companies is a significant investment, but it can offer lower operating costs over time. (Courtesy of Energy Recovery)

A pressure exchanger can help a CO₂ system save up to 15% of its annual energy, which first and foremost helps with operating costs. According to Energy Star, every dollar in supermarket energy savings is equivalent to increasing sales by $59. A pressure exchanger also improves the capacity of the system, helping address two concerns for system designers, store operators, and technicians. First, for existing systems, the option to add more capacity can help stores add refrigeration cases, for example, and not need to update the entire system. Second, frequent heat waves across the U.S. put pressure on refrigeration systems, so the extra capacity can be used as a safeguard to help protect against high-pressure discharge failure in case of extended heat wave events. 

Looking Long Term 

The switch to CO₂ for many companies is a look toward the long term. It’s a significant investment, but with environmental improvements and lower operating costs over time, the benefits begin to compound. 

Another long-term positive impact of CO₂ refrigeration (with a pressure exchanger) is the standardization of refrigeration systems across national chains. For many larger chains, depending on the climates across the U.S. and beyond, they may have to configure different systems -- oftentimes four or five different ways -- to account for capacity, water usage, evaporation, and more. This complicates the procurement process and training of service technicians.  

A CO₂ refrigeration system equipped with a pressure exchanger can handle nearly any climate, except for perhaps a very dry desert climate, which might need different configurations. In such a situation, a pressure exchanger can work in tandem with an adiabatic cooler to save more energy and minimize water usage. Even with this exception, pressure exchangers can greatly simplify CO₂ refrigeration systems for a large company, improving maintenance efforts and supply chain operations. 

In addition, the long-term forecast of CO₂ refrigeration shows that manufacturing capacity will catch up to the demand. While many American manufacturers are still primarily producing HFC systems, that is in the process of flipping, and more and more CO₂ systems will be available in the coming years. 

So, what does this mean for commercial contractors? Being ready to answer customers’ questions and being trained and educated on these systems is critical, not just to get more business, but to differentiate yourself from others in the industry. There are certainly questions and barriers to adoption, but walking your customers through the process and showing them the options available to them -- as well as the long-term benefits -- will set you up for success in this new era of commercial refrigeration.