Motion Control & Drives


Managing operational efficiency in food retail

April 2020 Motion Control & Drives

If you work in facilities or energy management for a food retailer, change is something you handle every day. When the way we live, work, or shop changes, new food retail technology is close behind.

Right now, all those things are changing like never before. Megatrends like electrification, digital communications and the fight against climate change are creating both opportunities and challenges for the food sector, worldwide.

Danfoss sees this first-hand because it works with hundreds of food retail chains in over 60 countries. The company has identified five big, overlapping changes that are combining to shape today’s supermarkets and five key ways to respond:

1. Pressure on operating margins makes cost savings essential: the average profit margin for a large food retailer currently stands at just 1,7%. In practice, this means that supermarket teams need creative ways to cut operating costs.

2. Increasing food safety and reducing food loss are more important than ever: according to the UN Food and Agriculture Organization, food wastage accounts for 3,3 Gigatons of greenhouse gas emissions. Avoiding food loss has always been essential to limit costs, now it is part of sustainability too.

3. Climate change regulation makes refrigerant choice critical: choosing an alternative with low global warming potential has growing advantages. The right refrigerant brings advantages in cost, regulation, availability, environmental impact, and sometimes tax.

4. Utilising waste heat as a resource: urban neighbourhoods will need new ways of meeting energy challenges. In some Nordic countries, retail stores divert around 30% of their excess capacity into heating homes in the surrounding area. This is a potential source of revenue.

5. Electrification is a challenge, but also an opportunity: as well as infrastructure, retailers need to find ways to prevent expensive short-term spikes in energy use. Those who can find flexibility in their energy demand may be able to cut costs.

Overlapping challenges that demand a coordinated response

These five trends influence each other. For example, the opportunity to reduce energy tariffs by optimising electricity demand is all the more compelling because of the need to find cost savings wherever possible.

In the same way, the changing food retail energy landscape needs a coordinated approach. According to Danfoss, there are five technical strategies which, when combined, will help supermarkets to stay ahead of and in some cases benefit from, society’s emerging demands.

1. Use smart refrigeration case control to reduce operating costs: too much cooling and you waste energy, too little and you risk food loss. An adaptive case controller, like the Danfoss ADAP-KOOL series, can balance refrigeration performance to the load. These advanced controllers connect to the Internet and the compressor pack controller via a system manager.

2. Connect to the Internet to eliminate food waste and cut service costs: connecting your refrigeration system to the cloud offers a host of possibilities to save money and improve food safety.

3. Treat refrigerant selection as a long-term decision: the refrigerant you choose has a significant impact on costs for the life of a store.

4. Integrate each store's systems to gain economies of scale: many retailers pay to run a heating and hot water system, while a separate refrigeration system releases heat into the atmosphere. Treating these facilities as an integrated solution can reduce a store's carbon footprint, while reducing installation and operating costs. When integrated, a store's refrigeration system can supply heat too, reducing the need for a boiler. Danfoss's purpose-built Heat Recovery Unit helps to eliminate the technical challenge.

5. Reduce energy prices by optimising demand: the fastest cost reductions are often found in managing demand patterns. Utilities companies are increasingly seeking help to match energy production to demand, discounting off-peak energy or seeking a temporary reduction in power use to manage short-term demand response events. There are several ways to achieve this, for example by using a battery bank, changing maintenance schedules, or storing energy thermally. This could include pre-cooling freezers or using an ice-making unit to load up with excess renewable energy.

It’s happening right now

Between them, these five approaches can help retailers to cut costs, minimise environmental impact and find a competitive advantage, while preserving food safety.

They’re best used in combination; for example, heat recovery is much easier with a CO2 system and smart case controllers maximise the benefit of monitoring online.

Danfoss calls this integrated approach Smart Store. Food retailers around the world are already using it to improve efficiency, find new opportunities and meet the sector’s current challenges head on.




Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Medium voltage drive for enhanced energy efficiency and process optimisation
Schneider Electric South Africa Motion Control & Drives
Schneider Electric South Africa has unveiled its cutting-edge Altivar Process ATV6100 medium voltage (MV) drive range, designed to enhance energy efficiency and operational reliability across various industries.

Read more...
Powerful high-precision hexapod
Motion Control & Drives
With the HEX150-125HL, Aerotech is launching the latest generation of its hexapod technology. The compact six-axis positioner combines precise movements with high load capacity and simple integration.

Read more...
Servicing the electric motor sector
Motion Control & Drives
Hexagon Electrical has expanded its manufacturing and service capabilities to meet the growing demand for customised, high-performance specialised electric motors in heavy engineering, and hazardous industrial and mining applications.

Read more...
Control system for deep antenna
Rockwell Automation Motion Control & Drives
When a major university in South Korea set out to build a 21-metre deep space antenna, the researchers needed a control system that could track celestial objects with pinpoint accuracy, a level of precision they thought was out of reach. By partnering with Rockwell Automation, they discovered that the right technology and support could turn their vision into reality.

Read more...
Manufacturers should go PFAS-Free
igus Motion Control & Drives
igus continues to develop engineered plastics that are free of per- and polyfluoroalkyl substances (PFAS-free) in response to mounting evidence of severe environmental and health hazards caused by the chemicals.

Read more...
South African paper producer partners with ABB
Motion Control & Drives
Neopak, a leading manufacturer of containerboard and paper products, has renewed its partnership with global technology company, ABB to upgrade the existing automation system at its Rosslyn Paper Mill in Pretoria.

Read more...
ABB supplies electromagnetic stirrer to world’s largest electric arc furnace
Motion Control & Drives
ABB has secured an order from Çolakoglu Metalurji. for an ArcSave electromagnetic stirrer to be installed on one of the world’s largest electric arc furnaces (EAF)

Read more...
Compact, powerful and green mini-picker
Motion Control & Drives
SkyJacks has introduced Jekko’s Mini Picker to the southern African market. This is a compact, highly versatile and environmentally friendly electric mini-picker that is set to redefine lifting capabilities across multiple industries.

Read more...
Redefining industrial lifting
Motion Control & Drives
The Konecranes S-series hoist redefines industrial lifting through its integration of a ground-breaking synthetic rope with smart features, a lifting capacity of 20 tons, and the ability to adapt to diverse girder configurations.

Read more...
Bühler drives innovation in agriculture and food processing
Motion Control & Drives
NAMPO 2025 is set to be one of the most significant agricultural events in southern Africa. It provides a unique platform for Bühler to showcase its advanced solutions that are designed to improve efficiency, sustainability and profitability in the agricultural sector.

Read more...