Designing and installing a cold-storage refrigeration system that needs to operate efficiently and perform consistently in Nogales, Arizona, one of the hottest ambient climates in the United States, is challenging enough. Doing this in a regulatory landscape limiting the use of legacy refrigerants also has the potential to steepen the challenges. However, in the case of a recent project lead by Bustamante Refrigeration and American Refrigeration Supplies, Inc. (ARS), regulations-driven technology transitions were embraced for the opportunities they presented to pioneer the use of a new-generation refrigerant and system.

 The project represents the area’s first successful installation of a cold storage refrigeration system using Chemours Opteon XL20 (R-454C)—supporting objectives including high performance operation, energy savings, a smaller environmental footprint and more. From the start, it was recognized that the success of a project of this scope depended on the collaboration of leading companies in HVACR who demonstrate a commitment to providing the industry with innovative technology that supports more sustainable solutions. Bustamante Refrigeration worked with ARS, Chemours, Heat Transfer Products Group (HTPG) and Copeland.

Aligning System Design with U.S. Regulations

The project was influenced by the U.S. EPA’s American Innovation and Manufacturing (AIM) Act, which is phasing down hydrofluorocarbons (HFCs). The AIM Act’s Technology Transitions Program will soon start requiring the use of lower GWP refrigerants in certain new equipment. Collaborators on the project recognized that these restrictions were working to transition the industry away from many of the refrigerants—such as R-404A, R-449A and R-448A—currently used in condensing units.

Consequently, the team looked at solutions supporting use of a new generation of mildly flammable A2L refrigerants, ultimately deciding on Opteon XL20 (R-454C) for the project. Opteon XL20 is a lower flammability, low GWP, hydrofluoroolefin-based (HFO) refrigerant that, along with several other HFOs, has deemed as acceptable, subject to use conditions, for various commercial refrigeration applications under the EPA’s Significant New Alternatives Policy (SNAP) Rule 26.

For low-temperature and medium-temperature refrigeration applications, Opteon XL20 provides an ideal alternative to legacy HFC refrigerants such as R-404A, R-507, R-448A, R-449A, and R-407 series fluids. Offering a GWP of 148 (AR4), Opteon XL20 meets many of the application-specific regulations requiring new system designs to utilize refrigerants with < 150 GWP. The system design was very similar to designs using nonflammable HFC refrigerants. Each condensing unit fed two Russell evaporators.

Within the condensing unit, there was a semi-hermetic Copeland discus compressor specifically designed and optimized for Opteon XL20. To maximize the energy efficiency of the system, each evaporator utilized an electronic expansion valve and state-of-the-art EcoNet control technology.

Now up and running, the system has realized energy savings through various methods, including:

• Reducing fan speeds during certain times to 50%;
• Optimizing compressor run time;
• Reducing icing issues and unnecessary defrosts;
• Improved product quality through minimal temperature fluctuations.
• Offers the option to be configured to control a condensing unit with single or multiple evaporators as a group.

For projects in the U.S. market that use mildly flammable A2L refrigerants such as Opteon XL20, refrigeration systems must comply with the relevant building codes and standards. Equipment must be specifically designed and approved by a nationally recognized testing lab (NRTL) for use with mildly flammable refrigerants. In many cases, such as this installation in Nogales, the largest change in equipment using A2Ls comes from the need to install mitigation technology in case of a refrigerant leak. This mitigation step included a factory-installed leak detector in the evaporator. This technology prompts a safety shut-off valve to minimize the amount of refrigerant that might leak into the occupancy.

“The transition to better, lower-GWP solutions we’ve been hearing about for years is now well underway, making it a pivotal and exciting time for the HVACR industry,” said Jeff Warther, senior consultant at Chemours. “Now that SNAP Rule 26 has cleared A2Ls for takeoff in commercial refrigeration, collaborations like this one in Nogales are going to become increasingly important in paving the way for industrywide adoption.”

Conclusion

The successful installation of new-generation cold-storage refrigeration technology represents a significant step forward for the commercial refrigeration industry’s transition to lower GWP solutions. It also demonstrates the impact already being made by pioneering projects happening ahead of the January 1, 2026, deadline for certain new equipment requirements, including condensing units, which need to comply with limits below 300 GWP for systems with under 200 pounds of charge or under 150 GWP.

A key benefit includes a lower total cost of ownership (TCO)—comprised of system investment and equipment operating costs, such as preventive and corrective maintenance, labor, parts and the fixed expense of energy consumption.

As businesses continue to move toward more sustainable commercial refrigeration solutions, collaborations are increasingly important for meeting the challenges and leveraging opportunities afforded by the latest A2L technology. Ongoing investments and innovations by HVACR leaders will continue to provide commercial refrigeration businesses with a robust selection of options to lower TCO, increase sustainability and remain competitive.