Carter Synergy designed and installed a bespoke R744 (CO₂) refrigeration system for the Granarolo Distribution Centre in Willenhall. The project serves four temperature-controlled areas within the facility: a chilled warehouse, a freezer, a freezer lobby and a chiller lobby.
The system was designed to meet the demands of a busy food distribution operation where reliable temperature control, energy efficiency and plant resilience are essential. Using natural refrigerant technology, the installation provides a low-GWP solution while maintaining the storage conditions required to protect product quality throughout the supply chain.
Two independent CO₂ refrigeration systems serve the four temperature-controlled areas. Distributing the load across two refrigeration packs provides additional operational flexibility and allows the facility to maintain dependable performance across its chilled and frozen storage areas.
Each cold room is fitted with ceiling-mounted evaporators, evenly distributed across both refrigeration systems to provide consistent cooling throughout the facility. The system was designed to suit the size, layout and operational requirements of the site, ensuring stable temperatures are maintained across all storage areas.
- 2 housed external C02 packs
- 2 gas coolers
- 2 de-superheaters
- 16 internal evaporators
- Bespoke external pipework cladding
Cold Room Dimensions (in metres):
- Main Chilled Warehouse: 71.7m (L) x 30.3m (W) x 11.85m (H)
- Main Freezer: 28.5m (L) x 12.9m (W) x 11.85m (H)
- Freezer Lobby: 12.9m (L) x 7.5m (W) x 11.85m (H)
- Chiller Lobby: 9.4m (L) x 6.8m (W) x 5.5m (H)
Together, these areas provide the chilled and frozen storage capacity required to support large-scale food distribution operations.
Control Systems & Integration
The project’s control systems utilise RDM (Resource Data Management), seamlessly linking the refrigeration system and leak detection to the building management system (BMS).
Integration is facilitated through BACNet communication protocols and custom TDB software.
Project Outcome
Carter Synergy delivered a reliable and sustainable CO₂ Refrigeration System for Distribution Centre operations through the installation of two energy-efficient R744 refrigeration systems at the Granarolo Distribution Centre. Designed to serve multiple chilled and frozen environments, the solution provides dependable temperature control, supports product integrity, and enhances operational efficiency, helping the facility meet the demands of large-scale food distribution while reducing environmental impact.