Entering A New Era of Refrigerant Management

New Demands

The proposed regulations introduce several seismic shifts that every food and retail operator – as well as their refrigeration contractor — must understand. First, the EPA has lowered the regulated appliance size threshold from 50 pounds of refrigerant to just 15 pounds. This seemingly small change brings thousands of previously untracked assets into the regulatory fold, creating an unprecedented data management challenge.

Second, the rule mandates HFCs to be included along with HCFC appliances as part of the mandatory leak inspections regime once an appliance leak rate crosses a threshold, introducing additional significant recurring operational cost (HFC appliances outnumber HCFC appliances by a huge number). For larger systems, those with a full charge of 1,500 pounds or more, the proposal calls for installing automatic leak detection (ALD) systems. Together, these changes dismantle the old ‘wait and see’ approach to maintenance and force a move toward proactive, data-driven oversight. The importance of marrying compliance with overall operations cannot be overstated here.

Navigating this new landscape is not merely about avoiding fines; it’s about building more resilient, efficient, and sustainable operations. It requires a strategic pivot from reactive repairs to proactive management. Here are the essential steps every operator should be taking right now:

1. Build your data foundation immediately. Begin a comprehensive inventory of all appliances containing between 15 and 50 pounds of refrigerant, as this exercise can take a long time to finish. Accurate charge size data is paramount, in addition to the date of installation, as well as the refrigerant type the appliance holds. This will also give you the opportunity to correct any data anomalies for existing appliances 50 pounds or more.
2. Prevent the chronic leaker designation. An appliance that leaks more than 125% of its full charge in a calendar year is designated a chronic leaker and must be reported to the EPA. This is not a list you want to be on. You need to have real-time tools and dashboards to pinpoint assets that can reach a 125% leak rate.
3. Modernize your recordkeeping and workflows. The 30-day window to repair leaks cannot be met with last-century recordkeeping. Relying on paper invoices and delayed data entry from service contractors is no longer a viable strategy. It’s time to mandate near-real-time data entry from the field. This is where modern connected operations platforms can make a significant difference. These systems allow operators to automate compliance workflows, connecting ALD systems with overall facilities management to streamline data collection, audits, and maintenance tasks.
4. Plan for new costs and regulatory procedures. Success in this new era requires a sophisticated understanding of both the regulations and the associated costs. There will be situations where a leak cannot be repaired within the 30-day timeframe. Operators must be fluent in the process for filing an extension with the EPA and developing a formal retrofit or retirement plan to gain regulatory relief.

Furthermore, it’s crucial to budget for the new reality of additional mandatory inspections. A common misconception is that an ALD system provides a blanket exemption, but it doesn’t. Inspections will still be required for any part of the system not directly monitored by sensors, representing a significant and often overlooked new operational expense. Since it is not possible to have leak sensors installed for the whole system, a different approach to leak monitoring involving a software solution is needed. There are various vendors in the market, including Facilio, that can help provide that solution. This is helpful, because if the whole system is monitored by the software, you are not required to perform mandatory leak inspections.

Strategic Imperative

As the landscape shifts toward stricter compliance measures, the role of technology-driven compliance becomes paramount. Gone are the days when compliance was a standalone effort. In today’s world, it’s essential to integrate compliance into your broader operational strategies. A connected computerized maintenance management system (CMMS), which integrates compliance functions directly into ongoing asset and maintenance management, ensures that compliance becomes embedded in every facet of operations. This integration creates a seamless process where compliance is automatically tracked, reported, and aligned with operational performance goals.

The operators who thrive will be those who embrace technology and data, treating refrigerant management as a core strategic function. By taking proactive steps today, businesses can not only ensure compliance but also forge more efficient, resilient, and ultimately more profitable operations.