Why CO₂ is the most promising refrigerant for modern food processing

The refrigerant landscape is undergoing rapid change. For decades, synthetic refrigerants such as CFCs, HCFCs, and HFCs were widely used across food production and industrial processing. But growing environmental concerns, stricter global regulations, and rising energy costs have accelerated the shift towards more sustainable, future-proof solutions.

In margarine, shortening, and specialty fats production, refrigeration is at the very heart of crystallisation and product consistency. For this reason, choosing the right refrigerant isn’t just a technical decision: it’s a business-critical one.

Among natural refrigerants, CO₂ (R744) has emerged as the clear frontrunner. Safe, efficient, and environmentally friendly, CO₂ delivers excellent thermodynamic performance while meeting the industry’s high demands for product quality, hygiene, and process reliability. It’s an option that not only meets today’s sustainability demands, but also delivers the reliability and cooling power required in these modern, high-capacity processing environments.

In this article, we’ll explore the problem with conventional refrigerants, why CO₂ is the most promising solution in margarine, shortening, and specialty fats production, and the practical benefits of CO₂ in factory environments.

For many years, the fat processing industry relied on synthetic refrigerants such as CFCs, HCFCs, and HFCs to power cooling systems and maintain the conditions needed for crystallisation.

These refrigerants offered efficiency at the time, but their environmental impact has become impossible to ignore:

• CFCs and HCFCs have been phased out worldwide due to their severe effect on the ozone layer.
• HFCs, while ozone-friendly, still carry an extremely high global warming potential (GWP) – in some cases thousands of times higher than CO₂.

In continuous production environments like margarine, shortening, and specialty fats processing, this reliance on synthetic refrigerants presents both regulatory and operational risks. Governments across the globe are tightening restrictions on high-GWP refrigerants, creating uncertainty and potential costs for manufacturers who continue to depend on them.

On top of that, rising energy costs and growing sustainability pressures are making it harder to justify refrigerants that are not only environmentally damaging, but also less efficient compared to newer alternatives. For producers who rely on stable cooling for consistent fat crystallisation, these issues make the transition to natural refrigerants more urgent than ever.

When it comes to balancing sustainability, performance, and safety, CO₂ (R744) has emerged as the most promising refrigerant for today’s food processing industry.

For margarine, shortening, and specialty fats production, where cooling precision is directly linked to product quality, CO₂ is more than just an alternative: it’s a better fit.

Here’s why:

Unlike synthetic refrigerants, CO₂ has a global warming potential of just 1 and doesn’t deplete the ozone layer. As a naturally occurring substance, it aligns with the food industry’s shift towards greener, more sustainable solutions while helping manufacturers stay compliant with tightening environmental regulations.

CO₂ has unique thermodynamic properties that make it highly efficient for high-pressure applications like scraped surface heat exchangers (SSHEs). Its ability to operate at higher pressures allows for faster and more consistent cooling, which is crucial for controlling fat crystallisation and ensuring uniform product texture. In fact, results show that switching from NH₃ to CO₂ can increase production capacity by up to 40%, giving processors more throughput without requiring major equipment changes.

Non-flammable and non-toxic, CO₂ is widely recognised as safe for use in food environments. This makes it ideal for continuous production lines where reliability and operator safety are non-negotiable.

In margarine and shortening production, crystallisation is the defining step that determines structure, spreadability, and texture. CO₂ cooling systems enable precise temperature control and consistent results – all while lowering operational costs through energy and long-term availability.

Beyond its environmental advantages, CO₂ also delivers tangible operational benefits that make it highly attractive for modern processing plants. In industries where space, uptime, and efficiency are critical, these factors can make a measurable difference:

• Compact system design: Thanks to the thermodynamic efficiency of CO₂, refrigeration systems can be built more compactly than those using traditional refrigerants. This allows manufacturers to save valuable floor space in an already tightly optimised environment.
• Lower refrigerant charge: Compared to some synthetic alternatives, CO₂ systems require a smaller refrigerant charge to achieve the same cooling effect. This reduces costs, minimises risk, and makes compliance easier, particularly as stricter safety and environmental regulations come into force.
• Reliable, long-term performance: CO₂ systems are robust, durable, and well-suited to continuous operation in demanding environments. With fewer maintenance requirements and long-term availability as a natural refrigerant, they help ensure stable production while reducing downtime and lifecycle costs.

Together, these advantages make CO₂ refrigeration not just a sustainable choice, but a practical solution tailored to the realities of food processing plants.

The transition to natural refrigerants is no longer optional: it’s a necessity for food manufacturers navigating tightening regulations and rising sustainability expectations. With CO₂ systems, producers can align cooling operations with ESG commitments, reduce their carbon footprint, and stay ahead of evolving global standards.

Beyond compliance, CO₂ represents a future-proof investment. Its proven efficiency, safety, and availability mean manufacturers won’t face the phase-outs or restrictions that continue to affect synthetic refrigerants. For businesses producing margarine, shortening, and specialty fats, this ensures not only operational stability, but also a competitive edge in an industry where sustainability is becoming a key market driver.

At Gerstenberg Services, we’ve long championed CO₂ as the natural refrigerant of choice. That’s why our Polaron Scraped Surface Heat Exchanger (SSHE) is specifically designed for direct cooling with CO₂ (R744).

Engineered for durability, precision, and consistent performance, our machines enable producers to embrace natural refrigerants without compromising on process quality or efficiency. With CO₂ and Gerstenberg Services, you’re investing in equipment – and a refrigerant – that’ll serve your business well into the future.