Understanding Refrigerant Leak Risks in Food and Cold-Chain Facilities
Food and cold-chain plants rely on refrigerants such as R32 and R290 for temperature control in storage, processing, and transport systems. While both offer improved energy efficiency and lower GWP compared to older alternatives, their flammability introduces significant safety and compliance challenges. R32 is classified as A2L (mildly flammable), while R30 is A3 (highly flammable). Even small leaks in confined or poorly ventilated areas can create explosive atmospheres, posing risks to personnel, equipment, and product integrity.
Regulatory frameworks such as the F-Gas Regulation (EU), ASHRAE Standard 15, and OSHA guidelines require continuous monitoring and rapid response to refrigerant leaks. Failure to comply can result in operational shutdowns, fines, and reputational damage. The cornerstone of compliance is a reliable refrigerant leak detection system designed specifically for the unique conditions of cold-chain environments.
Key Requirements for R32 and R290 Leak Detection Systems
1. Sensor Technology Selection
The choice of gas detection principle is critical. For R32 and R30, infrared (IR) and catalytic combustion sensors are most effective. Infrared sensors offer long-term stability, resistance to poisoning, and immunity to oxygen fluctuations—making them ideal for cold rooms and industrial freezers where environmental conditions vary. Catalytic sensors provide fast response and are cost-effective for large-scale deployment, though they require regular calibration and are sensitive to silicone vapors.
The GDE series from Shanghai Gewei Electronic Safety Equipment Co., Ltd. uses high-performance infrared and laser sensors with a lifespan exceeding 5 years, ±3% measurement accuracy, and automatic temperature compensation. These features ensure consistent performance in sub-zero environments where condensation and frost can degrade standard sensors.
2. Placement and Coverage Strategy
Detector placement must account for refrigerant density and airflow patterns. R32 is heavier than air (density ~1.8 vs. air), so sensors should be installed near the floor or on lower walls in equipment rooms. R30 (propane) is also heavier than air but diffuses rapidly, requiring detectors at multiple heights—especially near compressors, valves, and pipe joints.
In large cold storage facilities, a grid-based layout with detectors spaced no more than 6 meters apart ensures full coverage. For high-risk zones like refrigerant charging stations or mechanical rooms, detectors should be installed within 1 meter of potential leak sources. The GDC series offers RS485 bus communication, enabling daisy-chain wiring that reduces installation cost and simplifies network expansion.
3. Integration with Building Management and Alarm Systems
Standalone detection is insufficient. Modern systems must integrate with BMS, fire alarm panels, and ventilation controls. When a leak is detected, the system should automatically trigger exhaust fans, shut off refrigerant flow, and notify maintenance personnel via SMS or cloud alerts. The GM810/GM820 gas alarm controllers support modular expansion, multiple relay outputs, and compatibility with 4G/WiFi modules for remote monitoring via mobile apps or cloud platforms.
This integration is essential for compliance with EN 378 and IEC 60335-2-89, which mandate automatic ventilation activation at 25% LEL for A3 refrigerants. The controller can also log historical data, generate compliance reports, and provide audit trails for regulatory inspections.
Environmental and Operational Challenges in Cold-Chain Monitoring
Cold-chain environments present unique technical challenges. Temperatures can range from -30°C in blast freezers to +25°C in packaging areas. High humidity, ice buildup, and frequent door openings cause condensation on sensor surfaces, leading to false readings or sensor failure. The GDA series features a dust-proof and moisture-resistant design with IP66 rating and wide operating temperature range (-40°C to +70°C), ensuring reliable operation in extreme conditions.
Additionally, electromagnetic interference from compressors and variable frequency drives can disrupt analog signals. The GDE and GDC series comply with GB16838 electromagnetic compatibility standards, with shielded 4-20mA outputs and built-in surge protection to maintain signal integrity.
Compliance and Maintenance Best Practices
Regulatory compliance is not a one-time setup but an ongoing process. Regular calibration (recommended every 6 months), bump testing, and sensor replacement are mandatory. The GDE series supports pre-calibrated smart plug-in sensors, reducing downtime during maintenance. Its remote zero-point and span calibration function allows technicians to perform adjustments without entering hazardous areas.
All detectors should be certified to relevant standards: GB15322 for China, UL 2075 for North America, and ATEX/IECEx for Europe. The GDC series holds CCCF, CPA, and explosion-proof certifications, meeting both national and international requirements.
For large facilities, deploying an IoT-enabled cloud-based monitoring system provides real-time visibility across multiple locations. Alerts can be pushed to smartphones, and historical data can be analyzed to identify recurring leak patterns or equipment failures before they escalate.
Conclusion: Proactive Detection as a Compliance and Safety Imperative
In food and cold-chain plants, refrigerant leak monitoring is not optional—it is a core component of operational safety and regulatory compliance. Systems must be selected based on refrigerant type, facility layout, and environmental conditions. The integration of infrared/catalytic sensors, intelligent controllers, and cloud connectivity enables a proactive approach to leak management.
Shanghai Gewei Electronic Safety Equipment Co., Ltd. offers a complete portfolio of gas detection solutions—from high-precision detectors to scalable control platforms—designed to meet the demanding requirements of modern cold-chain operations. By implementing a tailored monitoring strategy, facilities can ensure worker safety, maintain regulatory compliance, and protect the integrity of temperature-sensitive products.