Project Summary
ODA was appointed to deliver the refrigeration design for a new multi-million-pound chilled and frozen fulfilment centre for a leading online retailer - the first facility of its kind in the UK.
The project required a resilient, energy-efficient refrigeration solution capable of supporting high-throughput operation, while aligning with the client’s long-term sustainability and future-proofing objectives.
Refrigeration Strategy
Working closely with the client, ODA assessed operational requirements, and calculated heat loads to define the most appropriate system strategy. The facility was designed to operate at an external ambient temperature of +35°C, with 70% resilience provided across two independent refrigeration systems.
A CO₂ (R-744) refrigeration solution was selected to meet environmental objectives and provide long-term compliance. The systems were designed to serve:
- Chilled storage at +1°C
- Frozen storage at -23°C
Energy efficiency and operational flexibility were prioritised using parallel compression, inverter-driven lead compressors, EC fans and electronic expansion valves.
Due to constraints on available plant space, external equipment selection was carefully considered. A V-block gas cooler configuration was adopted to deliver the required performance within the available footprint.
Integrated Design and Delivery
Environmental, safety and operational considerations were embedded into the design from an early stage, including noise control, capacity modulation and provision for future heat reclaim potential.
Key elements of the coordinated design included:
- System and plant resilience strategies to maintain operation in the event of a single plant failure
- Fire strategy coordination, including door positioning and access planning
- Condensation control through optimised pipework arrangements
- Enhanced evaporator airflow and defrost performance
- Coordinated leak detection and safety zoning
- Clear service and maintenance access routes
- Commissioning support, including a detailed commissioning intent document
ODA worked closely with the wider project team to ensure effective coordination of refrigeration services with other disciplines.
Outcome and Value
- First-of-its-kind UK facility for a major online retailer
- Low-GWP CO₂ refrigeration solution aligned with sustainability objectives
- High resilience and operational security built into the system strategy
- Coordinated, maintainable design supporting long-term operation
- Delivered on time and on budget, despite programme pressures and COVID-related constraints
ODA’s Role
- Independent refrigeration consultancy
- Refrigeration system strategy and detailed design
- Multidisciplinary coordination
- Commissioning support and technical assurance
