Compiled by Eamonn Ryan with technical input from Nigel Pengelly, managing member of VMG Consultants, and Frikkie Kleyns, technical manager at Elmec Airconditioning
To reduce energy usage and minimise waste, VMG Consultants is assisting Pick ‘n Pay in modernising the air conditioning systems across multiple stores with cutting-edge, energy-efficient technology. This upgrade is also preventing more than 15 tonnes of waste from being sent to landfills.
Old vs revamped box. All images supplied by Elmec Airconditioning.
During the 2020 renovation of Pick n Pay On Nicol, the retailer made a notable environmental impact by opting to refurbish its air handling units (AHUs) instead of replacing them completely.
Nigel Pengelly, managing member of VMG Consultants, explained that 14 stores have already benefited from AHU refurbishments, with another 17 set to follow. This process involves converting water-cooled packaged units to air-cooled ones, with a strong emphasis on reducing and reusing waste to promote sustainability. Each refurbishment keeps approximately half a tonne of non-recyclable polystyrene out of landfills, supporting the wider adoption of this eco-friendly approach.
“Existing equipment, which is 20 years old but essentially relies on technology which is over 40 years old and therefore was designed and installed using energy-inefficient technology – because there were no alternatives. By using new technology such as computer-aided design and sophisticated computer programs, today we can optimise a supermarket’s air- conditioning units and reduce the size and running costs of equipment required that are 30- 60% more efficient,” says Pengelly.
In one refurbishment project, Pengelly points out that a direct replacement would have cost Pick n Pay’s landlord approximately R13 million, whereas the refurbishment of the air-conditioning system amounted to just R8.5 million. “There are huge savings to be made if you do it right.”
Pengelly, a key figure in the refurbishment project, emphasises the notable benefits of utilising LG’s advanced control systems. “LG, along with other major manufacturers, now offers comprehensive control solutions for their equipment. This ‘one-stop-shop’ approach simplifies relatively complex control logic and ensures seamless compatibility with their highly technical equipment.”
LG EEV kit.
LG’s innovation goes beyond conventional air conditioning units. Its Smart 5 Controller, along with a matching I/O (input/ output) module, marks a significant advancement in control technology. This system offers full control over all HVAC components, extending beyond just LG’s own equipment.
“What sets LG apart is its high-quality ‘built-in’ control-programmes and ease of programming for the end-user. Unlike outsourcing alternative controls where software development might be tedious and fraught with time-consuming problems, LG’s controllers are supported by an inhouse team that produces tried and tested well-designed programs, which are constantly being improved and updated at no additional cost. This means you get advanced features without the need for extensive customised programming and expensive upgrades.”
Another major advantage of LG systems is the simplicity of on-site programming. The Smart 5 Controller’s user-friendly interface is accessible even to those without technical expertise. Pengelly commended the system for its intuitive design, which removes the need for costly and complex custom software solutions.
This technological upgrade aligns seamlessly with Pick n Pay’s sustainability objectives. By adopting these advanced LG systems, the retailer enhances energy efficiency while also lowering operational costs and minimising its environmental footprint.
Compact standard package unit converted.
Pengelly, who has been working with Pick n Pay for 35 years, comments on the retailer’s commitment to innovation and sustainability. “Previously, Pick n Pay’s fresh air systems were set manually and locked in place based on the maximum possible population density. By implementing CO₂ sensors, we’ve introduced a dynamic, responsive system that adjusts fresh air supply based on the actual store occupancy throughout the day.”
A standout feature of LG’s technology is its connectivity. The Smart 5 Controller can be monitored and adjusted remotely through a modem, enabling real-time control from virtually anywhere in the world. “We can make adjustments from our office or even a smartphone, no matter where the store is located. This level of remote control and programmability is a game-changer for maintaining and optimising air conditioning systems efficiently.”
Along with advanced controls, Pengelly has also suggested the installation of other cutting-edge equipment, such as VRF chillers. These chillers, which utilise inverter technology to adjust performance rather than relying on basic on/off cycling, deliver enhanced efficiency and greater reliability. “VRF chillers are a great example of how modern technology can enhance our systems. They provide precise control and are much more efficient compared to traditional chillers.” The inclusion of plug fans and other components from multiple suppliers, such as HC Aircon and Ziehl Abegg, further boosts the system’s efficiency. By sourcing these parts in bulk, VMG helps Pick n Pay achieve cost savings while maintaining high-quality performance. Additionally, the company secured a 10-year warranty on compressors from several respected manufacturers, thanks to their rigorous maintenance standards.
“The beauty of plug fans lies in their ability to provide exact air quantities with ease. Unlike traditional belt-driven centrifugal fans, which often require cumbersome adjustments to pulleys and belts, plug fans allow for straightforward tuning. This capability ensures that we can achieve the exact air flows we require and corresponding energy savings.”
Plug fans are especially efficient because their power consumption decreases substantially as airflow is reduced. “When we decrease the air flow by a small margin, the power consumption decreases significantly. This results in substantial energy savings, which is crucial for maintaining operational efficiency and reducing costs,” Pengelly explains.
Furthermore, the introduction of computer programs and advanced design tools has revolutionised the way air conditioning systems are designed and replaced. Previously, systems were manually designed using basic tools, often resulting in inefficiencies. “Forty years ago, system design relied on manual calculations and estimates. Even now, old systems are simply replaced on a ‘like-for-like’ basis with no consideration given that the original systems could well have been over-designed.”
AC Smart 5 Controller.
Today, the industry benefits from not only advanced computer programs but also artificial intelligence. However, some practices still remain stuck in the past. “The use of advanced design tools should be standard practice, not optional. We have access to powerful software that can perform detailed heat load analyses and optimise system design”.
Revamping air conditioning units is an ongoing process that demands careful planning and a critical approach. Pengelly explains that the success of a refurbishment depends on determining whether a unit can be effectively upgraded or if a full replacement is necessary. This evaluation often involves a detailed assessment of the existing system, weighing both the potential advantages and constraints of refurbishment.
Successful refurbishments often rely on strong collaboration with contractors and suppliers. For example, when faced with to speed up the process. In one Pick n Pay refurbishment, new equipment was urgently needed. By coordinating with the manufacturer and stressing the time sensitivity, the team was able to have a new unit manufactured in just six weeks, instead of the usual 12-week lead time.
In settings like supermarkets, where continuous operation is essential, the challenge lies in completing refurbishments swiftly while minimising disruption to daily activities. “It’s essential to plan refurbishments in stages, ensuring that air conditioning systems remain functional for as long as possible throughout the process. More peripheral work, such as painting and lighting, can be deferred in order to accelerate the installation and commissioning of the critical equipment”.
Refurbishment usually entails incorporating new components and technologies to boost performance. For example, HC Aircon and Ziehl Abegg supply updated parts like coils and plug fans, which are key to modernising older units. These components typically deliver improved efficiency and reliability over the original ones. “Refurbishing a unit is not a one-size-fits-all solution. It requires an engineering assessment to determine if refurbishment is feasible and cost-effective. Factors such as the age of the equipment and the condition of the existing structure must be carefully considered. The decision to refurbish is based on a thorough inspection of the existing unit. Only a relatively small proportion of units are considered suitable for refurbishment.
“By integrating modern components and utilising advanced technologies, refurbishment can extend the lifespan of older units while enhancing their efficiency. Effective refurbishment also requires a thorough understanding of engineering principles and cost considerations, ensuring that decisions are based on a comprehensive evaluation of the equipment’s condition and potential benefits
Elmec Airconditioning’s role in the Pick N Pay refurbishing project
Frikkie Kleyn, managing member of Elmec Airconditioning, highlights the company’s crucial role in refurbishing several Pick n Pay stores across the country. Kleyn underscores the remarkable progress made in shortening the refurbishment timeline, cutting downtime from 12–16 weeks to just 5–8 weeks. “The key focus is on minimising disruption to daily operations while ensuring quality work,” he notes. This shift not only saves costs but also enhances the shopping experience for customers.
Elmec’s refurbishment process includes comprehensive inspections of existing air conditioning units to evaluate whether they are suitable for refurbishment. “We have extensive experience refurbishing these systems. If a unit isn’t likely to last another 15 to 20 years, it doesn’t make sense to refurbish it.”
The refurbishment strategy includes complete overhauls of the air conditioning units. “We essentially strip everything down to the shell. Then, we replace all internal components, including wiring, coils and fans, ensuring everything looks brand new. The goal is for the client to feel like they’ve installed a new system, even if the outer shell is the original unit.”
He cites one of his greatest compliments received, which ironically was initially meant as a criticism: “The project owner’s national operations manager queried why there were a couple of small dents on what he assumed was a new box. He couldn’t believe it when I clarified that it was a refurbished 20-year-old box. Once he realised the context, he doubly appreciated the work we had done.”
Revamped Completed Box
Kleyn explains that the refurbishment project is designed to tackle several key issues, with a primary focus on reducing costs, enhancing environmental sustainability, and improving operational efficiency. “One of the main reasons for refurbishing the air conditioning systems is to provide significant cost savings compared to replacing the entire unit,” he explains. By refurbishing, they aim to retain some components, effectively ‘recycling’ materials rather than simply discarding them.
When asked how Elmec ensures refurbishments don’t disrupt Pick n Pay’s daily operations, Kleyn points to the importance of the preparation phase. “A significant portion of the work can be done while the existing systems are still operational,” he says. Most units they encounter are already partially failed, allowing Elmec to start preliminary work without affecting store performance.
“By using the available space in plant areas, we can install new condensing units and complete much of the pipework in advance. This way, by the time the new coils arrive, we’ve already done about 50% of the work.” In situations where full shutdowns are required, such as during the peak summer season, Elmec carefully schedules the refurbishments to minimise disruption. “We ensure that we do most of the heavy lifting during off-peak hours, often in the evenings,” he explains. This careful scheduling allows for seamless transitions with minimal downtime.
Kleyn also highlights the innovative LG Smart 5 controller, which significantly boosts the functionality of the refurbished systems. “This versatile controller simplifies programming and enables real-time monitoring,” he explains. The tablet-shaped device integrates seamlessly into the existing infrastructure, allowing technicians to manage and program the system without needing specialised software expertise.
The LG Smart 5 controller offers a wide range of inputs and outputs, delivering both flexibility and complete oversight of the refrigeration system. “It allows us to monitor critical parameters such as refrigeration pressures and system data,” Kleyn explains. This feature enables Elmec’s technical team to remotely diagnose issues before sending technicians to the site.
“This off-site monitoring is a game-changer as a standard feature without the addition of expensive building management systems (BMS). Unlike traditional systems where you can only check if a unit is on or off, the LG Smart 5 gives us detailed insights into system performance. This means we can address potential issues proactively, ensuring efficient operations for Pick n Pay.”
Coordination is vital in such a project. “VMG takes the lead on project management. They handle the design aspect and oversee the overall quality throughout the project. My role focuses on the installation and communication with suppliers and manufacturers, ensuring everything runs smoothly.” This coordinated approach ensures a smooth workflow, with VMG overseeing project timelines and quality control, while Elmec focuses on the technical details and installations.
Water cooled package unit converted to latest Pick n Pay specifications.
Commitment to quality work
“It’s all about passion,” Kleyn says. “I truly love what I do, and that passion motivates me to deliver the best possible results.”
He reflects on lessons from his father about the satisfaction of creating something remarkable from scratch, a mindset he applies to every refurbishment project.
“I’ve always had a knack for taking old items and revitalising them,” says Kleyn. “When Nigel approached me about this work a few years ago, I was excited to give it a shot. Since then, I’ve thoroughly enjoyed transforming these systems.”
Kleyn views each refurbishment as one-of-a-kind, stressing that no two projects are ever identical. “Every plant, every situation, every location presents different challenges and opportunities. I take pride in making each refurbished unit stand out, and it’s rewarding to see the reactions of clients when they walk into a space and see the improvements. “If I can achieve a sense of satisfaction from our clients, then I know I’ve done my part.
