Vol. 12, No.

1 January 2011

This Issue
3
PRODUCT SCENE:
NEW STANDARD TEXTURED WHITE FINISH,
BSG SERIES DEBUTS

6
PARTNERS IN SUCCESS:
H.E.L.P. HOUSE AND KOEHLER-BORDEN &
ASSOCIATES

Published by

Defrosting: Basics & Beyond, Part Two

Editors Note: This is the conclusion of a twopart article on walk-in cooler and freezer defrost
methods. In the last issue we defined traditional
defrosting. This time we move into an in-depth
discussion of Master-Bilts reverse cycle defrost
(RCD) method and how it can be integrated
into parallel rack systems as well as single
compressor condensing units. Thanks again to
Dave Entrekin, Master-Bilts national technical
sales manager, who wrote the article.
As discussed in the last issue, there are
three types of hot gas defrost: Bypass, three
pipe, and reverse cycle. Reverse cycle is
the focus of our discussion and it is more
commonly used in parallel racks than single
compressor systems.
A parallel, or distributed, rack system
is a multiple compressor refrigeration
unit piped in parallel and yielding energy
savings of 20% or more over a single
compressor unit (for more on Master-Bilts
PS series parallel models, see the Cool It!
July 2009 issue). Integrating hot gas defrost
methods into parallel racks additionally
increases overall efficiency.
Racks, by design, have a common
discharge (hot gas) header interconnecting
all compressors which makes reverse cycle
more practical in rack systems. This becomes
the source connected to the individual
circuit suction line through a solenoid valve.
A second valve isolates the suction line from
the suction header of the rack during defrost.
The cool gas or liquid refrigerant created by
the hot gas condensing in the cold coil is

safely routed through the liquid line back to

the liquid header of the rack.
A more challenging approach is to use
a single compressor condensing unit with
a reversing valve or two solenoid valves
to supply hot gas to the evaporator. The
backward flow is the same but there is a
risk of compressor damage if condensed
liquid refrigerant returns to the inlet of
the compressor. This liquid, if sufficient in
quantity, will not boil off completely upon
entering the compressor and will act as a
solvent diluting the oil within. This results
in reduced lubrication for the moving
parts of the motor and compressor sections
leading to premature failure.
A number of additional components have
been developed to protect the compressor
by returning the liquid to a refrigerant
gas. Suction accumulators are small tanks
that allow the liquid to expand and boil
off. Thermal bank assemblies have a tank
filled with a heat exchanging liquid thats
warmed by the hot discharge gas during
the refrigeration cycle. Re-evaporative
coils circulate warm ambient air to heat
the liquid and boil it. Valves to reduce the
return flow rate have been utilized. All of
these add complexity to the system.
However, the development of a digital
control system for walk-in coolers and
freezers paired with a stepper-type electric
expansion valve, Master-Bilt has developed
an RCD system that eliminates liquid
generation during defrost. This controller

COOL IT! Vol. 12, No. 1

Defrosting: Basics & Beyond, Part Two (cont.)

uses information from sensors on the
evaporator to monitor the outlet of the
coil and will detect the presence of liquid
refrigerant. The controller then reduces
the percentage of opening of the electric
valve slowing the flow rate and volume
of the refrigerant into the return line. This
allows complete vaporization to occur. The
resulting gas then presents no risk to the
compressor as it enters.

Reverse cycle defrost works through means of a reverse cycle valve which is installed in
either a parallel rack or single compressor refrigeration system. The photo above shows a
valve installed in a single compressor M-series condensing unit.

A further comparison with traditional

off-cycle or electric defrost quickly
demonstrates the improvements and
savings reverse cycle offers.
Defrost duration for a walk-in cooler is
reduced from 20 30 minutes to 1 2
minutes.
Defrost duration for a walk-in freezer
is reduced from 15 25 minutes to 4 6
minutes.

Temperature rise in walk-in space is

typically 1 2 degrees, much less than
traditional systems, so theres less heat to
be removed from the space.
Defrost heaters and coil return to operating
temperature, thus reducing refrigeration
run time.
Electrical consumption for compressors
running during defrost is on average 65%
less than resistive heating.
A complete defrost is assured as all coil
tubing and fins warm coincidentally not
incrementally (bottom to top, back to
front) as with electric heaters.
Ice buildup on freezer evaporator coils and
piping outside the finned area is prevented
as all tubing in the refrigeration system is
warmed during defrost.
Defrost of suction line piping prevents ice
buildup eliminating splitting of insulation
and subsequent water saturation.
Proper oil return to the compressor is
increased during each defrost cycle as hot
high density gas is used to flush the coil
and piping, rather than cool low density
suction gas, returning oil is carried
through the small liquid return line
creating higher velocity than in the larger
in diameter suction line.
The value of hot gas defrost has also come
to the attention of the U.S. Green Building
Council. It is one of the prescriptives listed
for LEED consideration of walk-in coolers
and freezers in their LEED 2009 for Retail:
New Construction and Major Renovations
document.
This citing is in Table 3, Page 35 (pdf
version), Item Evaporator, Attribute Hot
Gas Defrost. The document is online at www.
usgbc.org/ShowFile.aspx?DocumentID=7956.
Considering the increasing use of
parallel rack systems for larger foodservice
applications and the availability of a
compressor-safe single condensing unit,
reverse cycle defrost clearly becomes an
efficient and safe alternative to traditional
off-cycle and electric methods.

3
Product Scene
New Standard Textured White Finish
In the July issue we announced a new textured black
finish would be standard on all black cabinets. Taking it
a step further, weve changed our standard white finish
to textured as well. Besides the added aesthetic appeal,
the new finishes help minimize dents and scratches that
occur over time.

Master-Bilts new white finish is textured to add visual appeal and minimize
dents and scratches.

BSG Series Debuts

Master-Bilts latest sliding glass door merchandisers
are designed with both aesthetics and functionality in
mind. The BSG series features a contemporary roundedcorner design creating an attractive showcase. Each
model is also standard with five heavy-duty, welded
wire shelves per door providing ample merchandising
space for products. The cantilever shelves are twoposition and adjustable in one-inch increments to fit
individual display requirements. Price tag molding and
self-closing doors are also standard.
Available now, the BSG series comes in two sizes: the
52-inch wide BSG-48 and 78-inch BSG-74.

The new BSG sliding glass door merchandisers feature a contemporary

rounded corner design with plenty of shelving and optimal lighting to
maximize product display.

I wonder if illiterate people get the full effect of alphabet soup?

Jerry Seinfield

COOL IT! Vol. 12, No. 1

You Missed Work Because Of . . . What?

A survey by CareerBuilder.com collected some of employees more unusual excuses
for missing work. Here are some highlights:
An employee said his mother had been attacked by a chicken.
Another employee reported that his finger had gotten stuck in a bowling ball.
An employee simply told the boss he wasnt feeling too clever that day.
An employee said he needed to mow his lawn right away in order to avoid a lawsuit
from his homeowners association.
One employees foot got caught in a garbage disposal.
The day after Thanksgiving, one employee called in to say shed burned her mouth
on a piece of pumpkin pie.

The Cold Water Solution

Sam went to visit his Uncle Pete, who lived out in the country with his dog. Uncle
Pete served lunch, and as they were eating, Sam noticed that his plate didnt seem
completely clean. He asked his uncle about this.
Clean? Uncle Pete said. Theyre as clean as cold water can get them.
He brought Sam a drink, and the glass looked cloudy. As Sam examined it, Uncle
Pete just laughed. Now dont you worry, he said. Those glasses are as clean as
cold water can get them.
Finally Sam got up to go, but Uncle Petes dog, guarding the door, began to growl.
Sam looked at his uncle for assistance.
Oh, dont worry about him, Uncle Pete said. Come over here by me, Coldwater!

Movie Madness
If only real life was more like the movies. Then . . .
Everyone in New York City would live in a spacious, loft-style apartment,
regardless of how much money they madeor if they had a job at all.
If you had twins, you could count on one of them being evil.
You could always defeat invading aliens by planting a virus into their computer
systems with an ordinary laptop.
When youre outnumbered in a fight, the bad guys will always attack you one by
one instead of all at once.
When you turn out the lights, youll still be able to see clearly, but everything in the
room will turn blue.
Youd find that world experts on nuclear fusion or other advanced scientific
technology are usually blonde, beautiful, and under 25.

COOL IT! Vol. 12, No. 1

Upcoming
NAFEM Show
February 10-12, 2011
Orange County Convention Center
Orlando, FL

ApEx Show
April 3-4, 2011
Moncton, NB

North America Pizza & Ice Cream Show

February 20-21, 2011
Columbus Convention Center
Columbus, OH

Northwest Foodservice Show

April 3-4, 2011
Oregon Convention Center
Portland, OR

Canadian Restaurant & Foodservices

Association Show
March 6-8, 2011
Direct Energy Centre
Toronto, ON

NRA Restaurant Hotel/Motel Show

May 21-24, 2011
McCormick Place
Chicago, IL

New England Food Show

March 20-22, 2011
Boston Convention and Expo Center

In February Were Bringing The

Cold To Orlando.
And its all in booth 868.

BE SURE TO VISIT OUR GREEN ROOM SHOWCASING ENERGY EFFICIENT &

GREEN FRIENDLY PRODUCTS AND FEATURES.

6
Partners In Success
H.E.L.P. House And Koehler-Borden & Associates
London, Ohio
H.E.L.P. (His Ever Lasting Purpose) House is a community
outreach center located in London, Ohio that exists to
serve families and individuals in need by providing
food, clothing, shelter and emergency assistance. As
a food pantry it distributed 270,851 food items in 2010
and as a soup kitchen it served some 350 meals every
Monday night, plus an additional 500 on Thanksgiving
Day. With numbers that keep growing each year, they
need to be sure their refrigeration equipment is reliable
and ensures food safety.
In operation since 2000, the non-profit organization
relied on donated residential refrigerators and freezers
to house their inventory. Throughout the years
H.E.L.P. House accumulated 21 units that were located
throughout the warehouse wherever there was an
electrical outlet they could plug in to.
It was crazy running around to all the different
refrigerators and freezers to get the food items we
needed. Lets just say it wasnt that easy to find
the butter when you needed to, states B.J. Bryant,
community outreach, grant writer and administrator at
H.E.L.P. House. We knew there was a better answer
because we had seen walk-ins at other facilities but
never dreamed we could afford one.
However, when Bryant attended a United Way meeting
and met representatives from the local Community
Action Organization, she discovered the possibility of
getting a grant to pay for a walk-in. At that point, Bryant
had six hours to get the grant application in. Hoping
someone would get back to her in time, she reached out
to walk-in manufacturers via email, informing them she

was on deadline and had $12,000 to spend.

Matt Perry of Koehler Borden was her savior! In fact, he
was the only one who responded. Bryant plugged Perrys
numbers into her grant and submitted it with only 20
minutes until deadline.
H.E.L.P. House found out in August 2010 that they
would receive half of the grant but the walk-in needed
to be in operation by September 30 or they would not
get the second half. Mike Crossen, Master-Bilt regional
manager, and Tim Oehler of Koehler-Borden went to the
facility to iron out the details. For us this walk-in was a
significant change. Master-Bilt latched on very quickly to
our needs and didnt put us on the back shelf because we
werent a big customer, says Bryant.
The walk-in was installed on September 29, electrical was
completed the following day and the deadline was met.
H.E.L.P. Houses goal was to have the new walk-in
stocked and ready to go for their big Thanksgiving dinner.
For the past 10 years we had to beg grocery stores to
hold our turkeys until the Saturday of the outreach; then
wed have to start making the rounds at 6 am to pick
them all up and bring them to the House, says Bryant.
This year, thanks to Master-Bilt, we saved a lot of time,
effort and energy being able to stock all the turkeys in
our walk-in.
Investing in the new freezer paid off the minute it
was plugged in. H.E.L.P. House saw their electricity bill
decrease by 25%, and that was during the winter months
when the heat was working at maximum capacity. They
are also now able to store fresh produce in the 24 x 12 ft.
walk-in, something they didnt have room for before.
We are now able to serve more families more efficiently
because of Master-Bilt and our volunteers love it, too,
states Bryant.

We need your help!

To make Cool It! a better publication for all, we need your questions, comments and story suggestions.
Send in your ideas to Lynn Burge at lburge@master-bilt.com or fax them to 800-232-3966.

Published quarterly by the

Master-Bilt Sales & Marketing Department
Lynn Burge, editor

908 Hwy 15 North New Albany, MS 38652

800-647-1284 Fax: 800-232-3966
www.master-bilt.com