Refrigeration in supermarkets: CO₂ and intelligent controls

Supermarket refrigeration is entering a phase of profound transformation. New restrictions on fluorinated gases, the need to reduce energy consumption, and the growing availability of smart controls, remote monitoring, and predictive tools are changing both the choice of refrigerants and the architecture of the systems.

Technologies set to play an increasingly important role include CO₂ (R744) systems , along with distributed configurations and low-load solutions. At the same time, artificial intelligence and data analytics are becoming part of the daily management of plants, with the aim of identifying anomalies before they cause shutdowns, product losses, or excessive consumption.

CO₂ and new refrigerants are redesigning supermarket systems.

The first big change concerns the refrigerant.

In Europe, the F-Gas Regulation 2024/573 has already imposed very stringent limits on commercial refrigeration. For example, from 2022, centralized multipack systems for commercial use with a capacity equal to or greater than 40 kW cannot use fluorinated gases with a GWP equal to or greater than 150, with the specific exception of the primary circuit of cascade systems. For stand-alone equipment , the 150 limit will be effective from 2025, while from 2030 it will also affect additional categories of stationary refrigeration.

This framework is encouraging the adoption of refrigerants with significantly reduced climate impact . Non-fluorinated alternatives recognized by the European Commission include CO₂, hydrocarbons, and ammonia, along with synthetic refrigerants and low-GWP blends for certain applications.

In large-scale retail trade, CO₂ is particularly attractive because it allows for the construction of systems with very low GWP and reduces exposure to future restrictions on HFCs.

Available architectures are also becoming more diverse:

• centralized transcritical CO₂ systems;
• cascading configurations;
• distributed systems and mini-racks;
• self-contained hydrocarbon units;
• low-charge solutions;
• low-GWP synthetic blends, where still appropriate.

The direction therefore does not seem to be towards a single technology valid for all stores, but towards a greater specialization of the system based on size, climate, store configuration and renovation strategy.

Distributed and modular systems to simplify retrofitting and maintenance

Another important trend concerns the architecture of the systems .

Alongside large centralized racks , more modular and distributed systems are emerging , in which refrigeration production is divided among multiple units. This approach can facilitate gradual upgrades in existing supermarkets, avoiding the need to replace the entire system in one go.

For retailers, it can be particularly useful during renovations or conversions from existing HFC systems. The conversion can be organized by area or user group, reducing the impact on store operations.

A distributed configuration can also offer some advantages :

• reduction of overall refrigerant charge;
• greater modularity;
• possibility of intervening on individual sections;
• less dependence on a single large circuit;
• greater flexibility in retrofits;
• simplification of some service activities.

The downside is a larger number of distributed units and components, which requires effective oversight and a good maintenance strategy.

Precisely for this reason, the growth of modular systems proceeds alongside the diffusion of remote monitoring and centralized controls.

AI and remote monitoring enter cold management

The second major transformation concerns digitalisation .

Supermarket refrigeration systems produce a large amount of data: temperatures, pressures, consumption, alarms, defrost cycles, door openings, compressor operation, and setpoint trends.

More advanced monitoring software can use this data to identify anomalous patterns and performance degradation before the problem becomes apparent.

Artificial intelligence can be used , for example, to:

• identify recurring anomalies;
• support fault diagnosis;
• assess the likelihood of a loss;
• optimize setpoints and condensation pressures;
• improve defrost management;
• compare performance between different outlets;
• prioritize maintenance tasks.

The goal isn't to replace the technician, but to provide more useful information before they arrive on-site . Effective remote diagnostics can reduce the time needed to identify the cause of the problem and increase the likelihood of solving it during the first intervention.

In the food retail sector, this aspect is particularly important because a system failure not only entails a technical cost: it can compromise the continuity of the cold chain and food preservation.

Energy efficiency and maintenance are becoming increasingly integrated

Refrigeration represents one of the main energy consumers in a supermarket . Even relatively small improvements in regulation can therefore produce significant results when applied to an entire store or a network of stores.

European ecodesign legislation considers energy consumption during the use phase to be one of the most significant environmental aspects of refrigeration equipment used for direct sales, such as display cases and refrigerated cabinets in supermarkets.

For this reason, strategies such as:

• floating condensing pressure;
• setpoint optimization;
• advanced defrost management;
• fan regulation;
• early detection of leaks;
• heat recovery;
• predictive maintenance;
• continuous comparison between actual and expected performance.

The future of supermarket refrigeration therefore seems to emerge from a combination of several elements: low-GWP refrigerants, modular architectures, charge reduction, digitalization, and data-driven maintenance.

It won't be a single technology that will transform the industry, but the integration of refrigeration, control, and efficiency. And it's precisely this integration that makes the supermarket an increasingly attractive environment for the evolution of commercial refrigeration.