Saving Energy in Refrigeration Technology with AI
Berlin-based start-up Factor4Solutions is developing an AI-powered solution to significantly reduce energy consumption and CO2 emissions in refrigeration systems.
In Germany alone, refrigeration accounts for around 16 percent of electricity consumption and generates over 20 million tons of CO2 annually. Using AI-supported software, Factor4Solutions is introducing a fully automated solution for all types of refrigeration systems, which can save up to 75 percent of the annual electricity required. The solution is immediately deployable, manufacturer- and technology-independent, scalable, and applicable to both existing and new buildings. The “system manager” operates as a stand-alone, offline-capable system, making it suitable for critical infrastructures. The concept behind the AI-driven system manager is the result of over ten years of research by Factor4Solutions’ founding team at TU Berlin.
Digital Twins of Refrigeration Systems
A major issue in refrigeration is that recooling plants and pumps often consume as much electricity as the refrigeration units themselves, yet this is rarely recognized. Additionally, energy optimization is often performed only at the component level and typically for a single operating state defined during the planning phase—one that occurs in less than three percent of all operating hours. This leads to unnecessary electrical energy consumption of up to 90 percent during many operating hours.
The intelligent system manager from Factor4Solutions addresses this challenge by considering the operation of all components relevant to refrigeration technology and their energy-related operating costs together. To achieve this, the solution creates a digital twin of the respective refrigeration system, which is used to calculate how the individual components should behave in real time or in parallel with operation, as well as situationally, to achieve maximum system efficiency.
Efficiency-Based System Operation Reduces Costs, Power Consumption, and Emissions
The cooling generators and all auxiliary units are no longer operated in a fixed sequence. Instead, they are activated and controlled by the solution based on efficiency, depending on weather conditions and the required output, using standardized protocols. In this way, the fully automated system manager ensures the most efficient system operation under every load situation. Users can set their desired optimisation targets individually, such as cost reduction, power consumption savings, or CO2 emission reductions.
The core business of Factor4Solutions is the operation of the system manager for users who purchase the hardware and use the software under a licensing model. The costs for users are calculated on a pro-rata basis, based on the savings achieved. Additional services, such as engineering support and subscription offers like energy reporting, complement the manufacturer’s offerings.
