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Case study
Beverage bottling plant lowers energy
costs with compressor technology upgrade
A national food and beverage corporation had to increase production of one of its
beverage bottling plants in order to keep pace with sales growth. This called for an
increase in refrigeration capacity, which traditionally would have translated into higher
energy costs to run the new equipment.
Instead, the company desired a solution that would reduce the cost of providing
refrigeration, and asked a Johnson Controls Frick Factor representative to develop
a strategy to accomplish this. Frick Factor is an authorized seller of Frick industrial
refrigeration products. Johnson Controls absorbed the Frick product line through its
acquisition of York International.
Challenges
• Increase the overall refrigeration capacity, while making the equipment less
expensive to operate.
• Perform the retrofit without disrupting the bottling production process and without
the need to enlarge the size of the engine room’s existing footprint.
• Reduce the cost of annual maintenance and the associated compressor downtime.

Frick RWF II Screw Compressor
Johnson Controls solutions
• Replace two aging reciprocating compressors with one new Frick Vyper
Variable Speed screw compressor package with a larger capacity and that fits
into the same footprint as the old equipment.
• Install a new refrigerant-based oil cooling system that avoids increasing the
existing compressor water cooling system.
• Provide a state-of-the-art compressor that is designed to minimize annual
maintenance.
Results
• Reduced the annual electrical energy consumption of the refrigeration
equipment by more than 30 percent within the first year of operation.
• Created consistent product quality by removing the sudden load swings
experienced during the bottle filling process.
• Lowered the plant’s compressor maintenance budget by $22,000 per year.
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