Report on the remanufacturing of refrigerated display cabinets

©Centre for Remanufacturing & Reuse 2009
The quality of cases used in remanufacturing means that, when compared with
lower cost models, issues arise which result in larger outlays. For example a
new, low-quality unit may have a fault with a single component, but dismantling
problems may make it more cost effective to scrap the RDC and buy new.
Examples such as this have resulted in service lives of less than four years for
lower quality new RDC models.
Customisation
Another driver discussed was dissatisfaction with the standard products available.
Very little customisation could be requested with new models, as they are mass
produced. The extent of retailer influence over the model was limited to visible
cosmetic factors, such as colour and design of shelving. For greater control over
these factors, one retailer specially commissioned the design and production of
their own RDCs. This allowed EoL considerations to be factored into design, and
units were created modularly, allowing easier reclamation of components at end
of service. Under the customer‟s control, design for deconstruction was also
considered: For example, joints were not welded and wear parts were easy to
access for maintenance. These cabinets are being remanufactured regularly.
Overall, however, the environmental benefits of remanufacture are only a
secondary consideration.
Upgradeability
In recent years, remanufacturing or refurbishing units has been perceived as a
way of increasing energy efficiency without having to replace the full range of
RDCs. An example was quoted where the hot gas defrost process had been
modified to an „off cycle‟ 9 . Existing casings were reused, but the valves and other
components were removed and replaced. Although not classed as complete
remanufacture (since the warranty was limited), significant efficiency savings
were realised; further these types of upgrades could be relatively simply
incorporated into fully remanufactured units.
Another example involved the installation of new, more efficient fan motors.
12,500 were exchanged by one retail chain in 2008. RDCs were taken from one
store, remanufactured, and then cascaded as replacements in the following store,
leaving minimal waste. These replacements reduced the heat generated during
running, reducing the need for further cooling. Although the cost to upgrade the
cabinets was substantial, running cost savings of £2.25 million per annum were
realised resulting in a pay-back period of approximately one year. In addition,
CO 2 e savings of 21,000 te per year were realised.
9 This type of unit has no defrost timer or heaters. It operates on the basis of the refrigerator operating at a
temperature high enough to defrost the coil when the compressor is not running.
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