Case Study of Using ‘NewTon’Natural Refrigerant Refrigeration Units | High-efficiency refrigeration unit adopted in BCS's latest frozen/chilled warehouse

02/11/2023

Samurai Asia Editorial Department

Introducing a case study of using the natural refrigerant refrigeration unit "NewTon", one of Mayekawa (Thailand)'s core products, in Thailand. In this article, we will introduce the background and benefits of the installation of this system in the newly built frozen/chilled warehouse of BANGKOK COLD STORAGE SERVICE, LTD.

BCS Warehouse No. 3, a large frozen/chilled storage operated by Kawasaki Kisen Group

BCS, whose parent company is Kawasaki Kisen Kaisha, Ltd. ("K" LINE), a major Japanese integrated logistics company, was established in Thailand in 1989 and has been providing high-quality frozen/chilled logistics services and logistics solutions for the Thai market. The company completed construction of its third cold storage, BCS3, in July 2023.

▲ Exterior of BCS3

BCS3 is a state-of-the-art frozen/chilled warehouse that employs ASRS (automated storage and retrieval systems: a retrieval system that automates storage, sorting, collection, and picking operations) inside the freezer. Mobile racks are used in the chilled and temperature-controlled storage areas to speed up loading and unloading operations. The warehouse is also equipped with two process rooms for food processing, and is designed to meet the diverse needs of customers.

▲ ASRS equipment in BCS3

▲ The inside of BCS cold storage No. 3

At the heart of the frozen/chilled warehouse that is full of cutting-edge technology, Mayekawa's refrigeration unit "NewTon" was adopted as the refrigeration equipment.

High-efficiency compressor for environmentally friendly ammonia refrigerant that can operate with small amounts of ammonia

Mayekawa's NewTon has been used at CLK Cold Storage Company Limited, a group company of Kawasaki Kisen in Vietnam, and its excellent energy-saving effects were highly evaluated, which led to the decision to use it in BCS3.

“BCS3 has been in operation for several months now, and we are beginning to get data showing its energy-saving performance. Its energy consumption is considerably smaller than that of conventional refrigerating facilities. We have high expectations for its further energy-saving effects in the future. Another advantage of NewTon is its small amount of ammonia charge. For environmental reasons, our company has a policy of using ammonia, which is an efficient and natural refrigerant, rather than refrigerants with high GWP (global warming potential). Ammonia is a refrigerant that must be handled with care from a safety standpoint. Currently, BCS3 is operating with an ammonia charge of 176 kg. This is significantly less ammonia than our previous facility.” (Mr. Wisarut, BCS)

Freezer warehouse compressor Mayekawa Thailand

▲ NewTon installed in BCS3

Ammonia refrigerant is an excellent refrigerant with a high heat value obtained per unit power. The impact on global warming is extremely small, and the burden on the environment is kept to a minimum. NewTon deploys an indirect cooling method using the natural refrigerant ammonia to cool CO₂. Ammonia circulates only in the unit installed in the machine room, and CO₂ cooled with ammonia is sent to the unit cooler in the freezer/chiller. This keeps the amount of ammonia charged to the minimum necessary.

Unlike conventional ammonia systems, the oil-dissolved refrigerant does not circulate to the freezer/chiller, so oil does not accumulate in the coils of the unit coolers inside the freezer/chiller. Therefore, high performance can be maintained without degrading the performance of the unit cooler due to aging. Additionally, there is no risk of damage to the cargo due to ammonia leakage, which is an important point when storing the precious cargo of our customers.

Freezer warehouse compressor Mayekawa Thailand

▲ Hermetic screw compressor mounted on NewTon

Overhaul and various maintenance carried out in Thailand Reliable after-sales service provided by Mayekawa

"Another reason we have chosen NewTon is that it is maintenance-free. Our maintenance staff only needs to manage the cooling water, and very little special care is required. Refrigeration equipment is the heart of a frozen/chilled warehouse and is a machine that can never be stopped. Thanks to the extensive support provided by staff of Mayekawa (Thailand), our maintenance staff can manage the equipment with peace of mind every day. Mayekawa's experienced staff handle overhauls locally in Thailand, which is very reassuring in the unlikely event that an unexpected situation arises. From the after-sales service aspect as well, we feel once again that the NewTon system from Mayekawa was the best choice for us.'' (Mr. Wisarut, BCS)

NewTon requires only an oil change at the time of overhaul, and does not require oil draining as in conventional ammonia equipment. The newly developed screw compressor with its hermetic structure integrating compressor with motor, eliminates concerns about refrigerant leakage from mechanical seals as with conventional types. Such a maintenance-free system with ammonia can be said to be a technology unique to Mayekawa.

▲ From left: Mr. Surasit / Mr. Wisarut of BSC and Ms. Thepkesorn / Ms. Natthiyaporn / Mr. Arnon of Mayekawa (Thailand)

BANGKOK COLD STORAGE SERVICE, LTD.
Mr.Surasit Najaiyen / Maintenance Manager and Safety Officer
Mr.Wisarut Kunlapatsuwan / Assistant General Manager

Mayekawa (Thailand) Co., Ltd.
Ms.Thepkesorn Seelonk / Business Development
Ms.Natthiyaporn Phitaksathid / Business Development
Mr.Arnon Khongsorn / Engineer

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