Overview
When a leading UK seafood supplier developed a new 15,000m² National Distribution Centre in the North West of England, Orwell Design Associates was appointed to design the refrigeration system for the facility's chilled and frozen storage areas.
Our consultancy team developed a complete refrigeration design that balanced energy efficiency, operational resilience and long-term maintainability, supporting the client's expansion plans while ensuring the facility was ready for future demands.
The Challenge
The new distribution centre included one chilled chamber operating at +1°C and two large frozen chambers operating at -22°C. Designing an efficient refrigeration solution for multiple temperature zones required careful consideration of system performance, sustainability and ongoing operational costs.
The project also presented several engineering challenges, including long pipe runs, plant room congestion, heat reclaim requirements and the need to commission the facility within a demanding programme.
Our Approach
ODA developed a bespoke CO₂ transcritical booster solution, selecting a configuration that delivered high levels of efficiency while providing resilience and flexibility across the site.
The design incorporated heat reclaim for warm glycol defrost and underfloor heating, alongside carefully engineered pipework layouts to accommodate long pipe runs, minimise pressure losses and maintain reliable oil return. Plant room ventilation and service coordination were also fully integrated into the design to maximise safety, accessibility and ease of maintenance.
Our scope also included airlock dehumidification, ductwork, air blade systems and load shedding strategies, ensuring the refrigeration system worked efficiently as part of the wider facility.
Key Elements
- CO₂ transcritical refrigeration system
- Chilled and frozen storage design
- Heat reclaim for defrost and underfloor heating
- Plant room and ventilation coordination
- Airlock dehumidification and air blade systems
- Load shedding strategy
- Energy-efficient, maintainable system design
The Outcome
By combining detailed engineering with a consultancy-led approach, ODA delivered a refrigeration solution that met the client's operational, environmental and programme requirements. The system was successfully commissioned on schedule, allowing the facility to receive product as planned while providing a robust, energy-efficient solution designed for long-term performance.
