How Refrigerant Choice Affects Maintenance in Commercial Systems
Commercial refrigeration systems are engineered to deliver precise temperature control, but the refrigerant inside them does more than just cool—it shapes how the entire system performs and how often it needs maintenance.
Choosing the right refrigerant affects wear and tear on components, impacts energy usage, and even determines the type and frequency of servicing required.
As commercial refrigeration technology advances, so do the choices available to system designers and facility managers. With evolving regulations and a push for sustainability, selecting the right refrigerant is no longer just about temperature—it's a strategic decision with operational consequences.
At Solid Refrigeration, based in Bloomington, MN, we've seen firsthand how refrigerant selection can influence maintenance schedules and long-term system performance.
Businesses across the Twin Cities rely on us not just for installations, but for reliable refrigeration maintenance that takes these variables into account.
In this article, we'll explore five key questions to help you understand the critical role refrigerants play in your system's upkeep.
Comparing the Different Types of Commercial Refrigerants
Refrigerants are categorized into several major types, including chlorofluorocarbons (CFCs), hydrochlorofluorocarbons (HCFCs), hydrofluorocarbons (HFCs), hydrofluoroolefins (HFOs), and natural refrigerants such as ammonia (R717), carbon dioxide (R744), and hydrocarbons like propane (R290).
Each type varies significantly in terms of chemical composition, pressure, environmental impact, and compatibility with system components. For example, CFCs and HCFCs were commonly used in older systems but are now largely phased out due to concerns about ozone depletion.
HFCs, while ozone-friendly, have high global warming potentials (GWPs), which have led to the rise of HFOs and natural alternatives.
From a maintenance standpoint, these differences have practical implications. Older systems using HCFCs such as R-22 are becoming cost-prohibitive to maintain, not only due to rising refrigerant prices but also because of limited availability and dwindling technician familiarity.
Conversely, systems using HFOs or CO₂ may require advanced technician training and specialized components to handle higher pressures or different oil solubility characteristics. For example, CO₂ systems require careful management of transcritical cycles and specific heat exchangers that may not be present in traditional systems.
Choosing between these refrigerant types is not just a matter of cost or efficiency—it also impacts maintenance logistics. Systems running on natural refrigerants may reduce environmental liability but could require more frequent leak detection, corrosion management, or ventilation.
Understanding these variables can help operators schedule refrigeration maintenance that aligns with the system’s refrigerant profile.
Impact of Refrigerant Properties on System Performance & Upkeep
Refrigerant performance characteristics—such as thermodynamic efficiency, heat transfer capability, pressure-temperature relationship, and chemical stability—directly influence how efficiently a commercial refrigeration system runs and how much maintenance it requires.
Refrigerants with high energy efficiency can reduce compressor load, extend system life, and minimize wear on moving parts. Conversely, refrigerants that require high discharge pressures or operate near equipment limits can accelerate component fatigue and increase failure risk.
For example, systems using ammonia benefit from excellent heat transfer efficiency, requiring smaller charge volumes and yielding high performance.
However, ammonia is toxic and requires strict monitoring and leak prevention protocols.
Meanwhile, refrigerants with poor miscibility with lubricants may increase oil return issues in the compressor, leading to reduced reliability unless specifically engineered for that behavior. These technical nuances dictate how often systems should be inspected, flushed, or have oil levels tested.
Different refrigerants also affect evaporator and condenser performance due to variation in boiling points and heat absorption rates. These variations influence frost buildup, defrost cycles, and coil cleaning schedules.
With each refrigerant option, system tuning must account for its physical behavior under operating conditions, making refrigeration services more complex and personalized.
Environmental Considerations When Selecting Commercial Refrigerants
Environmental impact is now a major factor in refrigerant selection. Regulatory and market pressures are pushing the industry away from high-GWP refrigerants like R-404A and R-507A toward low-GWP HFOs and natural refrigerants.
Ozone Depletion Potential (ODP) and GWP are two critical metrics: modern refrigerants aim for zero ODP and as low a GWP as possible. While HFOs like R-1234yf and R-1234ze offer low GWPs, they may come with trade-offs such as mild flammability or limited compatibility with legacy components.
The choice of a refrigerant impacts not only compliance with environmental regulations but also long-term operational sustainability. Leaks of high-GWP refrigerants are costly both in environmental impact and in recovery or replacement.
Systems charged with environmentally friendly refrigerants can reduce carbon footprint, but often require specialized training and infrastructure for proper handling and containment. This affects preventive maintenance plans and the skill level needed for technicians servicing the system.
When planning upgrades or retrofits, facility managers must consider how each refrigerant aligns with sustainability goals and the potential cost implications of mandatory phase-outs.
Selecting an eco-friendly refrigerant is a proactive strategy that minimizes regulatory exposure and supports maintenance practices aligned with modern standards, even if it means investing in new components or training.
How Refrigerant Compatibility Shapes Maintenance Protocols
Refrigerant compatibility extends beyond system design—it’s a maintenance concern that affects everything from compressor longevity to valve performance.
Certain refrigerants are chemically aggressive to elastomers, gaskets, and lubricants, requiring routine inspections and replacement schedules that match their chemical profiles.
For instance, retrofitting a system from R-22 to an HFC or HFO blend without updating seals or oils can lead to material degradation and leaks.
Systems designed for synthetic oils like POE may suffer if a refrigerant with low oil solubility is used, potentially causing poor lubrication and compressor wear.
Incompatibility can also manifest in expansion valve behavior or sensor inaccuracies if the system was calibrated for a refrigerant with different pressure characteristics. These subtle mismatches may not trigger immediate failures but often result in increased service calls, efficiency losses, or premature part replacements.
Maintenance teams must tailor their procedures to the refrigerant in use. Filter-drier selection, flushing agents, and even pressure gauges must match refrigerant specs.
Compatibility with legacy equipment is also a consideration—some refrigerants can only be used with certain compressors or line set materials. These factors necessitate a maintenance strategy that accounts for material aging, chemical exposure, and refrigerant-specific behaviors.
Understanding Regulatory Compliance for Refrigerant Use
Refrigerant regulation is complex and evolving. In the U.S., refrigerant use is governed by multiple agencies, including the EPA under Section 608 of the Clean Air Act, which regulates refrigerant handling, leak repair thresholds, recordkeeping, and technician certification.
The phasedown of HFCs under the American Innovation and Manufacturing (AIM) Act further limits the availability and use of high-GWP refrigerants. Non-compliance carries financial penalties and can halt operations during audits or inspections.
Facility operators must be aware of both federal and state-level rules. States such as California have adopted more aggressive timelines for phasing out certain refrigerants, and the refrigerant chosen today may face future restrictions.
This uncertainty affects how systems should be maintained. Regular leak inspections, recovery documentation, and refrigerant tracking systems are not just good practice—they're often required.
Refrigerant labeling, storage, and cylinder tracking must all meet safety codes. Technicians must use recovery equipment certified to meet EPA standards. This regulatory backdrop turns refrigerant maintenance from a routine task into a compliance-driven process.
Staying ahead of these requirements minimizes liability and ensures safe, uninterrupted operations for commercial systems.
Partner with Solid Refrigeration for Expert Refrigerant Management & Maintenance
Navigating the complexities of refrigerant selection, performance, compatibility, and compliance is no small task, especially for businesses relying on commercial refrigeration systems for critical operations.
At Solid Refrigeration, we specialize in providing comprehensive support for every phase of refrigeration system management—from installation and retrofitting to routine maintenance and regulatory compliance.
With a focus on engineered energy management and turnkey solutions, our services are designed to keep your systems efficient, safe, and up to code.
If you're looking to optimize your refrigeration systems or need help selecting the best refrigerant for long-term performance and compliance, we're ready to assist.
Contact Solid Refrigeration at 952-854-2850, or request a free estimate through our website. With our dedicated support, your refrigeration systems will remain reliable, compliant, and cost-efficient year-round.