In industries that use cooling systems in their production processes energy use is a major concern. Energy costs have always been a factor in the profitability of these businesses, but recent events and price spikes have brought this into sharper focus.
As well as cost, environmental concerns and the need for UK businesses to achieve Net Zero status by 2050 are also causing headaches. These cooling systems, comprising industrial chillers to refrigeration units, are crucial for ensuring product quality and safety, yet they can be energy-intensive, driving up operational costs and also contributing to environmental impact. As businesses increasingly prioritise energy use and sustainability, the need for more accurate and comprehensive data to evaluate chiller performance has never been greater. One metric that provides such data is the Seasonal Energy Performance Ratio (SEPR) which is emerging as an essential measurement tool in the realm of process cooling, providing businesses with a more realistic and comprehensive understanding of energy use over time.
What is SEPR?
SEPR evaluates the efficiency of industrial chillers throughout the year. Unlike traditional metrics such as the Energy Efficiency Ratio (EER), which measures efficiency at a single operating point under controlled conditions, SEPR accounts for real-world variations. It assesses chiller performance across different cooling loads and fluctuating ambient temperatures, providing a more holistic view of its actual energy consumption throughout a typical year. This is particularly important in industries where cooling demands vary seasonally, making SEPR an essential tool for accurate, long-term performance evaluation.
How Does SEPR Differ from SEER?
While SEPR is gaining traction in industrial applications, it is often confused with SEER (Seasonal Energy Efficiency Ratio), which is more commonly applied in comfort cooling systems like air conditioning. The main difference lies in their application: SEER focuses on energy efficiency in residential and commercial cooling, taking into account outdoor temperature variations. By contrast, SEPR is designed specifically for process cooling applications, accounting for the unique challenges of industrial environments, such as varying production demands and the need for cooling under diverse conditions. SEPR considers a broader range of factors and provides a more accurate picture of efficiency in these settings.
For instance, chillers may operate under different cooling loads throughout the year, working harder during summer months and less during winter, which is why SEPR’s seasonal approach provides a more realistic view of their energy consumption.
This is especially relevant given the typical lifecycle of industrial chillers, which are generally replaced every 10 years. By using SEPR, businesses can make more informed decisions about their cooling systems, ensuring that they choose equipment that will provide optimal efficiency and cost savings throughout its lifecycle.
Selecting Energy-Efficient Process Cooling Equipment
In industries such as food and beverage and pharmaceuticals, cooling systems play a crucial role in ensuring product safety and consistency. These sectors rely on precise temperature control to meet strict regulatory standards and maintain product quality. While energy-efficient chillers reduce energy consumption and lower operational costs, their real value comes from providing more reliable and consistent cooling. This ensures that temperature-sensitive products maintain their integrity throughout the production process. For instance, in food manufacturing, precise cooling can prevent spoilage or microbial growth, ensuring that products meet safety standards without generating waste.
Focusing on equipment with a higher SEPR allows companies to make smarter choices that contribute to long-term sustainability while meeting regulatory requirements. Just as a higher Miles Per Gallon rating reflects a car’s ability to travel further on less fuel, a higher SEPR score indicates that a chiller provides more cooling with less energy consumption. This makes SEPR an effective and transparent metric for businesses seeking to balance energy efficiency with the performance needed to meet the demands of their industries, helping them to reduce costs while maintaining the high standards required for product quality and safety.
Total Cost of Ownership Data
When selecting process cooling equipment, some businesses may still choose to focus solely on the initial purchase cost, often overlooking the long-term costs associated with energy consumption, maintenance, and potential downtime. This is where a Total Cost of Ownership (TCO) approach becomes invaluable. By considering not only the upfront cost but also the operational expenses over the chiller’s lifecycle, companies can make smarter decisions that deliver significant savings over time.
SEPR reflects a chiller's real energy consumption throughout its operational life. This makes it easier to identify models that will use less energy and improve efficiency, thereby lowering the overall TCO. By selecting chillers with higher SEPR ratings, businesses can reap the benefits of long-term savings, especially in industries where cooling is a critical part of production.
Calculator tools are now available that allow businesses to compare the SEPR of different chiller models, enabling them to make data-driven decisions that will maximise both energy savings and efficiency. By considering the SEPR ratings at the time of equipment selection, companies can ensure they are investing in solutions that deliver the best return on investment over time.
Efficiency Comparison: TCS vs Conventional Chillers
To illustrate the practical advantages of selecting chillers with high SEPR ratings, consider the comparison between a high-efficiency TCS260 A HT chiller (SEPR 6.03) from Atlas Copco and a conventional chiller with a lower SEPR rating of 5.01. The difference in efficiency is substantial, with the TCS260 A HT having the potential to save an impressive 72,298 kWh of energy annually. At today’s cost of 30p per kWh this would equate to a cost saving of £18,097 and a reduction of 18.88 tons of CO2 emissions per year, which is the same as charging 1,249,297 smartphones over the course of one year.
Looking at these savings over a 10-year period, the benefits become even more pronounced. Over the span of a decade, the TCS260 A HT chiller could save 722,975 kWh of energy, which translates to a net cost saving of £168,487. In terms of environmental impact, this represents the carbon sequestered by 7,552 trees. From another perspective, this is the equivalent of avoiding the CO2 emissions from 45 gasoline-powered passenger vehicles driven for one year, highlighting how the long-term savings from selecting a high SEPR-rated chiller mirror the kind of sustained efficiency seen in high-MPG vehicles.
Conclusion
Because of the fluctuating cost of energy, the concerns around energy security and the focus on sustainability data-driven decisions are becoming more embedded in industrial operations, making SEPR an indispensable tool for evaluating process cooling systems. By providing a more comprehensive and realistic assessment of chiller performance, SEPR enables manufacturers to select the most efficient equipment for their specific needs, resulting in significant energy savings and reduced environmental impact. As industries continue to innovate and optimise their energy use, adopting SEPR as a key metric will be essential for staying competitive and sustainable in an increasingly eco-conscious marketplace.
Now is the time to evaluate your current cooling solutions and consider the long-term benefits of adopting equipment with a high SEPR rating. By doing so, you can reduce your energy consumption, lower your operational costs, and contribute to a more sustainable future.
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