Modernizing commercial refrigeration for a global tech giant

Modernizing commercial refrigeration for a global technology giant

Standardizing complex liquid cooling portfolios with a scalable, natural-refrigerant engineering platform

7 min Lesen

Overview

A leading global manufacturer of commercial refrigeration systems and display equipment, operating within a major food-retail technology group and serving the North American market primarily, wanted to modernize its cooling portfolio. The objective was to transition from an R448A-based micro-distributed refrigeration platform to natural refrigerant R290, while reducing product complexity through standardization, improving scalability and driving cost reduction.

The client needed a standardized condensing unit (CDU) platform that could support a wide range of refrigeration cases without multiplying Stock Keeping Units (SKUs), engineering effort or operational overhead. At the same time, the new platform had to align with stringent safety, compliance and efficiency requirements.

To achieve this, the client partnered with HCLTech. We delivered an end-to-end engineering solution that transformed multiple application-specific variants into a future-ready four-SKU standardized R290 CDU platform capable of supporting 150+ refrigeration case applications.

The Challenge

For transitioning to a future-ready portfolio, the client had to navigate several complex engineering and operational hurdles:

R448A to R290 transition: Moving to R290 required tight charge-limit management, ignition-source segregation, enclosure safety measures and alignment with UL 60335-2-89 and DOE efficiency expectations.
Standardization at scale: The client wanted to replace multiple application-specific CDUs with the minimum number of standardized SKUs capable of supporting medium- and low-temperature case applications.
Coverage across 150+ applications: The platform needed to flex across different case sizes, capacities and mounting styles while maintaining consistent performance and controls architecture.
Complex engineering decisions: Teams needed a practical Application Guideline that simplified heat-load mapping, component sizing, charge estimation, pressure-drop calculations and line sizing into fast, accurate selections.
Pilot-build validation: The new platform had to be physically built, integrated and tested through brazing, leak checks, vacuuming, charging and instrumented performance validation before scale-up.

The Solution

HCLTech Engineering and R&D services team partnered closely with the client to co-create a standardized R290 CDU platform designed for scale, performance and long-term readiness. The joint efforts resulted in

Design of a four-SKU standardized R290 CDU portfolio supporting 150+ refrigeration case applications across multiple case sizes, temperature classes and mounting styles.
Completion of end-to-end refrigeration engineering, including compressor, condenser and expansion valve sizing.
Condenser sizing and liquid cooling calculations that cater to a wide range of flow rates and temperatures of input liquid.
Optimization of line sizing, pressure-drop calculations and refrigerant charge management for safe, efficient operation.
Development of an A3-safe enclosure and electrical architecture aligned with UL 60335-2-89 requirements and DOE efficiency expectations.
Integration of controls, sensors, VFDs and communication modules for dependable field performance.
Creation of complete engineering assets, including 3D models, drawings, BOMs, wiring diagrams and validation inputs.
Support for prototype fabrication, brazing, leak testing, vacuuming, charging and performance validation.
Development of an Application Guideline and engineering decision framework for faster, more accurate CDU selection across engineering, applications and order-entry teams.

By combining engineering depth with hands-on deployment support, we helped convert a complex transformation program into a production-ready platform.

The Impact

The standardized CDU platform delivered measurable business outcomes across engineering, operations and sustainability.

Four SKUs now support refrigeration case applications, significantly reducing portfolio complexity.
Faster and more accurate engineering and order-entry decisions through a unified selection framework.
Lower execution risk with production-grade engineering documentation and pilot-build validation.
Improved manufacturability and serviceability through a common external footprint across all CDU variants.
Enhanced compliance readiness through safety-first R290 design and validated performance parameters.
Accelerated sustainability goals through migration from HFC refrigerants to natural refrigerant R290.
Stronger supply-side readiness with coordinated sourcing and RFQ management across 50+ suppliers for scale-up planning.

Conclusion

With HCLTech as its engineering partner, the client successfully transformed its refrigeration portfolio into a simpler, smarter and more sustainable platform.

The new R290 CDU architecture enables scalable growth without added complexity, while positioning the organization for future regulatory demands and evolving customer expectations. By combining deep product engineering expertise with execution excellence, HCLTech helped turn a strategic vision into a market-ready reality.

FAQ

What is R290 and how is it different from earlier refrigerants?

The R290 is a new type of refrigerant. It is more environmentally friendly, with reduced ozone depletion. In the US, regulations require all new equipment to transition to these nature friendly refrigerants.

What is UL 60335-2-89 and why is it important?

This is a safety standard applicable to commercial refrigerating appliances chillers and freezers. The engineering design must comply with and pass the requirements defined in this standard.

A3 Safe:

A3 Safe refers to a specialized safety enclosure designed to safely manage A3-class refrigerants, which are classified as highly flammable.

To mitigate the associated risks, an A3 Safe system incorporates:

Sealed enclosure design: All refrigeration components are housed within a fully enclosed sheet metal structure that prevents the spread of flammable refrigerants.
Isolation from external environment: The structure is engineered to remain isolated, ensuring that any refrigerant leakage is contained within the enclosure.
Leak detection system: Integrated sensors continuously monitor for refrigerant leaks and enable early detection to enhance operational safety.

In large refrigeration systems—where cooling machinery relies on refrigerants—this approach ensures that even if a leak occurs, it is contained, detected early and prevented from causing hazardous conditions.