The Problem
A long-standing pharmaceutical customer in North Wales needed to decommission a key refrigeration system serving an airlock to their critical freezer facility. While the airlock itself doesn’t hold stock, its function is vital to the integrity of the main freezer.
The core challenge was two-fold: The existing system was being removed as part of wider site works undertaken by ICE, creating an immediate need for replacement. At the same time, the client needed a future-proof solution that would remain compliant with the F-Gas phase down regulations, avoiding the inevitable service bans and risks associated with older, high-GWP refrigerants.
In the pharmaceutical industry, system downtime is not an option, making a seamless, expert led transition essential.
The Solution
ICE was commissioned to design and install the replacement refrigeration system. Our deep understanding of pharmaceutical temperature control and regulatory requirements made us the ideal partner. We have also been the sites service partner for over 20 years.
We specified a direct expansion (DX) system utilising R454C refrigerant. With a Global Warming Potential (GWP) of less than 150, R454C is fully compliant with all current and future F-Gas phase-down deadlines. We installed a 5.11kW capacity system, featuring a fully housed Danfoss Optyma Plus condensing unit and a Kelvion evaporator cooler. To ensure safety, and given R454C’s “mildly flammable” (A2L) classification, our design incorporated a mandatory leak detection system within the airlock.
The Outcome
The new system was successfully commissioned and handed over in October 2025, providing the customer with a state of the art solution that delivers three primary benefits:
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Compliance: By choosing the ultra-low GWP R454C refrigerant, the airlock system is fully future-proof against upcoming F-Gas phase down regulations.
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Reliable Operation: The high-efficiency Danfoss/Kelvion system provides robust and reliable temperature control for the airlock, directly safeguarding the integrity of the critical freezer operation.
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Maximum Value, Zero Friction: ICE provided a complete, audit-ready handover, managing all compliance documentation, including the critical PED Certification and mandatory A2L leak detection system installation. This seamless process ensured minimal disruption to the pharmaceutical site and secured the asset for the long term.
