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Last summer, The ACHR NEWS featured an article about Hunter’s Shop ‘n Save in Wolfeboro, New Hampshire, which burned down in January 2023. Owner Dan Craffey was determined to rebuild, and on June 20, 2024, he opened a new 16,000-square-foot store, which is 25% larger than the original. He also decided to install the FlexCube Supermarket Refrigeration System, a cutting-edge technology that uses the A2L refrigerant R-454C.
Recently, we checked in with Craffey to see how the technology was working, and he praised the new system enthusiastically. He noted that the store is running perfectly and that the refrigeration technology has cut his electric bill by about two-thirds. He added that the cases maintain perfect, stable temperatures regardless of outside conditions and that product loss has been significantly reduced. In short, he couldn’t be happier.
Energy Savings
The FlexCube modular system consists of identical 2- by 2-foot cubes that are easy to install and require no floor space, said James LaBrecque, founder and chief technology officer of FlexWare Control Technology LLC. Designed for both low- and medium-temperature applications, each cube contains about 25 pounds of refrigerant, and the modular design allows store owners to add more FlexCubes as needed for expanded space or additional refrigeration. By utilizing the A2L refrigerant R-454C, which has a GWP of 148, the FlexCube system meets federal regulations for low-GWP alternatives.
The new Hunter’s Shop ‘n Save required five FlexCubes with small-capacity compressors to service the various low- and medium-temperature cases located on the sales floor. Eight heat pumps, each with a capacity of either 1.5 or 2 tons, handle the store’s HVAC. While the cubes are all identical, they can use three different capacity Copeland scroll compressors, in order to vary the load as needed. Reclaimed heat from the cubes is used to heat the store — which is kept at 68°F year-round — as well as the Walgreens next door.
After reviewing Craffey’s recent electricity bills, it’s clear that the energy savings at the new store are impressive. The monthly electric bill for the older, smaller store averaged about $12,000 in 2021, while the monthly bill for the new, larger store is around $5,100, despite rising energy costs (the December 2024 bill came in at just under $4000, compared to $12,000 in December 2022 for the previous smaller store). Heating costs for the store, which once reached $70,000 to $80,000 annually, are now about $4,000 a year. In addition, the system helps maintain stable temperatures year-round, enhancing the shopping experience while preserving product freshness.
MODULAR SYSTEM: FlexCube modules can be put into standard production as soon as the store’s load is calculated. (Courtesy of James LaBrecque)
“The customers love shopping here, because the temperatures are very conducive to a great shopping experience,” said Craffey. “We have FlexCubes on top of the produce case and on the meat cooler and the produce cooler, so the equipment doesn’t take up any real estate. We were able to put a lot more cases in the store, because we didn’t have to build a compressor room in the back. And it’s extremely quiet. There’s nothing on the roof, so there are no fans rattling, which makes the neighbors happy. There’s a fluid cooler outside, but that’s extremely quiet. Overall, it’s just been a perfect experience.”
More Benefits
While Craffey is ecstatic about his lower electricity bills, he’s also thrilled with the savings on equipment, installation, and construction costs. His new refrigeration system came in at less than $1 million, far lower than other systems that, according to Craffey, would have cost at least four times as much.
“And that’s just the equipment savings,” he said. “If you’re building a new store, you can save a huge amount in construction costs, because you don’t need a stronger roof to hold the heavy refrigeration equipment and condensers. There’s also no backroom for the compressors, so you don’t need to build that space. Additionally, the system requires much lower electrical service. My store only uses around 200 amps, compared to 1,500 amps in most supermarkets, so that means less electrical infrastructure.”
The new system also allowed Craffey to open his store much sooner — in just six months, compared to the 18 months he said it would have taken if he had chosen a CO2 system. This quick turnaround time allowed the store to open a year earlier, generating profits that essentially paid for the entire system, he said.
In addition, maintenance is simple, requiring only periodic filter changes, and if a case door is left open, employees are notified to close it promptly. The store is also equipped with a smaller generator, designed to meet its lower power needs and ensure operation during potential outages.
Craffey is so pleased with the system that he plans to retrofit two of his other grocery stores with the FlexCube system as well. He noted that the compact design and low energy requirements make it ideal for repurposing spaces like former department stores or office buildings, which may lack the infrastructure needed for traditional rack or CO2 systems.
“Everybody who comes to see the system asks, ‘What’s the catch? What am I missing?’” said Craffey. “There is no catch, and you’re not missing anything. It’s an incredible system. I encourage everyone to come and see the store in Wolfboro. We’ll show you how the system is put together, and you’ll be amazed.”