Refrigerant Gas Detection: Improving Food Processing Safety

In the food processing industry, reliable HVAC systems are essential for maintaining safe, efficient operations and protecting product quality. Shaun Evers, managing director of Stonegate Instruments, discusses the risks posed by refrigerant gas leaks and how smart gas detection technology can help processors improve safety, efficiency and environmental compliance.

There are many types of food processing facilities, and while each has its own unique requirements, all share a common dependency on well-functioning heating, ventilation and air conditioning (HVAC) systems.

Beyond maintaining a comfortable and safe working environment, these systems preserve air quality by filtering out pathogens, allergens and other airborne contaminants that can compromise both food safety and staff wellbeing. They also play a critical role in maintaining cold chain integrity throughout processing, storage and distribution.

While these systems are of enormous operational value, they are susceptible to refrigerant gas leaks – most systems leak refrigerant gases, with the Carbon Trust estimating the average leakage rate in UK systems to be around 20% per year – that can endanger employees, raise operating costs and cause lasting environmental damage. 

Health hazards

For food processors that rely on refrigeration and cold storage, a major risks is the potential health hazards caused by exposure to refrigerant gases. Without taste, odour or colour, the gases’ presence can go unnoticed, which is a concern given that in the UK, it is estimated that 60% of gas escapes before anyone notices.

When exposed to these gases, employees can suffer from a range of health complaints, including nausea, headaches, coughing, breathing difficulties and skin and eye irritation. The danger is more severe for those confined or trapped in spaces like cold storage units, where higher concentration levels have the potential to cause unconsciousness or even asphyxiation. Some refrigerants are also flammable, creating an additional fire risk in environments where high-temperature processing takes place. 

Efficiency and environmental implications

Another hidden problem with refrigerant gas leaks is that they reduce the efficiency of HVAC and refrigeration systems – HVAC systems are already one of the largest consumers of electricity, accounting for up to 40% of a facility’s energy usage.

As gases escape, the systems need to work harder to maintain temperature control and in doing so, consume more energy. With most leaks not identified until 60% of the gas has escaped, some food processors could be paying an unnecessary 33% extra to operate their refrigeration systems.

An unidentified leak will eventually result in refrigeration system failure. This can cause significant damage to equipment, requiring costly repairs while putting perishable produce in storage at risk, with obvious financial consequences.

For food processors operating on tight production schedules, unplanned downtime can quickly disrupt operations, delay orders and increase the risk of product spoilage or recalls.

Leaking refrigeration systems can also have a profound effect on the environment. They use R32 coolants which, despite their high efficacy, contain hazardous hydrofluorocarbon gases (F-gases). F-gases are climate super pollutants, with a global warming potential thousands of times greater than CO2. When released, they persist in the atmosphere for decades, intensifying climate change and contributing to ozone depletion.

Leak detection and monitoring are now mandatory depending on system size. Equipment containing five tonnes of CO2 equivalent or more must be checked annually. Systems with 50 tonnes require checks every six months, while those above 500 tonnes must be inspected quarterly and fitted with automatic leak detection systems.

Penalties for non-compliance are significant. The UK’s Environment Agency can issue fines of up to £200,000 for offences such as failing to carry out checks, not installing mandatory detection equipment, or continuing to operate with banned refrigerants.

For food processors, however, the consequences extend beyond fines – non-compliance can disrupt production, damage brand reputation, and harm customer confidence. In an industry shaped by strict retailer compliance expectations and supply chain pressures, even minor disruptions can have significant commercial consequences.

Smart gas detection 

While there are several things that can be done in the case of a suspected leak, nothing can replace the accuracy and efficiency of using specially designed technology for this task. Whether a leak results from mechanical damage, equipment failure or poor maintenance, a gas detection system can help prevent a minor incident from becoming a crisis.

In fact, designers and manufacturers of electronic equipment for the refrigeration and HVAC industries continue to work diligently to improve the effectiveness of refrigerant, toxic and combustible gas sensors, with modern sensors boasting greater intelligence and capabilities to combat risks posed by toxic and non-toxic gases.

Thanks to rapid technological advances, the latest generation of sensors and systems features intelligent detection capabilities and ultra-sensitive performance. Equipped with advanced semiconductor or infrared sensing elements, they can be configured to detect specified gases in pre-calibrated refrigerant/air mixtures.

This means they can be tailored for different operating environments, ensuring that both toxic and non-toxic gases are detected effectively, even in large food processing plants and extreme settings, such as cold storage units. Furthermore, active filters that ignore gases of no interest help extend the sensor’s lifespan.

The latest gas detection systems also feature signalling alarms, LEDs that indicate the presence and status of each sensor, together with audio/visual alarms. These ensure that employees can be quickly alerted, and the leak promptly attended to, minimising risk.

These technologies don’t just help with gas leaks, but also with the detrimental effects of poor temperature control. Smart thermometers and temperature displays enable the monitoring and optimisation of refrigeration systems so that they function at the optimal temperature for the specific items they store. Should any temperature anomalies occur, the system will alert staff so that spoilage can be prevented. Open door alarms offer similar benefits.

For food processors, HVAC systems are the backbone of safe and efficient operations, yet their reliance on refrigerant gases creates hidden risks that can compromise safety, inflate energy costs, and damage the environment. Smart gas detection technologies offer the precision and reliability food processors need to stay compliant, safeguard employees, and maintain product integrity.

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FAQs

What is refrigerant gas detection?

Refrigerant gas detection uses specialised sensors to identify refrigerant leaks in HVAC and refrigeration systems allowing operators to respond before safety environmental or operational problems develop.

Why is refrigerant gas detection important in food processing?

Food processors rely on refrigeration to maintain product quality and food safety. Early leak detection protects employees prevents spoilage improves energy efficiency and supports regulatory compliance.

What are the health risks of refrigerant gas leaks?

Exposure to refrigerant gases can cause headaches nausea breathing difficulties skin irritation unconsciousness and in confined spaces potentially fatal asphyxiation. Some refrigerants also present a fire risk.

How do refrigerant gas leaks affect energy efficiency?

As refrigerant escapes cooling systems become less efficient forcing compressors to work harder increasing electricity consumption operating costs and equipment wear.

Are refrigerant gas detection systems required by law?

Yes. UK regulations require leak inspections and automatic leak detection systems for refrigeration equipment above certain CO₂ equivalent thresholds depending on system size.

How do smart refrigerant gas detection systems work?

Modern systems use semiconductor or infrared sensors to continuously monitor refrigerant concentrations trigger alarms identify specific gases and provide real-time status information.

Can refrigerant gas detection reduce maintenance costs?

Yes. Detecting leaks early prevents major equipment failures reduces emergency repairs extends equipment life and minimises costly production downtime.

What other technologies help protect refrigeration systems?

Smart temperature monitoring digital thermometers and open-door alarms complement refrigerant gas detection by helping maintain correct storage temperatures preventing spoilage and improving overall refrigeration efficiency.