German refrigeration manufacturer Teko has detailed the installation of a 103kW (29.3TR)-capacity CO2 (R744) booster system for a “challenging” refurbishment project at a 2,220m2 (23,680ft2) Rewe supermarket in the Lindenhof district of Mannheim, Germany.
The project presented unique challenges due to the store’s urban location, nestled beneath a senior living home and flanked by residential buildings just 10m (33ft) away. This demanded minimal noise from the new refrigeration system and a space-conscious solution that maintained full store operations throughout the 11-week renovation.
One of the most significant hurdles was installing the system’s radial gas cooler, which, due to space and architectural restrictions, could not be mounted outside. The project team was also not permitted to alter the building’s envelope. Instead, engineers from Teko and installation partner Koch Kälteanlagenbau decided to install the cooler in the building’s basement with a ducted exhaust system to expel warm air.
This setup not only met acoustic and spatial demands but also resulted in improved energy performance due to the lower ambient temperature of the basement, reducing energy consumption.
“This project proves what’s possible when experience, technology and teamwork converge,” Teko said in a LinkedIn post about the project.
“This project proves what’s possible when experience, technology and teamwork converge.”
Teko
Future-proof refrigeration
The new ROXSTAsmart CO2 rack has replaced the supermarket’s 15-year-old R134a/CO2 cascade system – also manufactured by Teko. The store’s previous system contained 200kg of R134a, which has a 100-year GWP of 1,530 and a 20-year GWP of 4,140.
“For Rewe this means future‑proof refrigeration, whisper‑quiet operation and maximum energy efficiency,” explained Teko.
The new system offers a cooling capacity of 79kW (22.5TR) for medium-temperature (MT) applications and 24kW (6.8TR) for low-temperature (LT) demands. It supports 60m (197ft) of MT refrigerated cabinets, 20m (66ft) of service counter, 40m (131ft) of LT freezer cabinets, six MT cold rooms and two LT rooms.
As part of the remodel, closed-door cabinets were also installed to further improve energy efficiency.
Alongside the CO2 rack and gas cooler, the project included the installation of four EC fans and six Whiteline evaporators, which serve the store’s eight cold rooms.
The system has been fully operational since October 2024 and is reportedly achieving a temperature delta of 3°C (5.4°F) compared to ambient conditions, an “outstanding value” for this type of installation, according to Teko.
