Regulation, efficiency and the future of process cooling
21 January 2026 
As environmental and efficiency regulations tighten across UK manufacturing, Atlas Copco’s Chris Ferriday spoke to PWE about how policies such as the F-Gas phase-down and Ecodesign requirements are reshaping process cooling by driving long-term shifts in efficiency, refrigerant choice, and digital connectivity across industrial operations
Recent changes to environmental and energy-efficiency legislation have significantly altered how UK manufacturers approach process cooling. The combined impact of the EU’s F-Gas phase-down and Ecodesign requirements has made environmental responsibility a central factor in technical and investment decisions.
“These policies have fundamentally changed how manufacturers approach process cooling,” says Chris Ferriday, Business Line Manager for Process Cooling Solutions at Atlas Copco. “The F-Gas phase-down, in particular, has accelerated the move away from high-GWP refrigerants and towards more sustainable, low-impact alternatives. At the same time, Eco-design requirements have placed efficiency at the heart of equipment design, pushing the industry to deliver measurable performance improvements rather than incremental gains.”
Ferriday explains that this shift has affected every stage of Atlas Copco’s product development process. “For us, that has meant embedding compliance into the design stage – not just to meet current regulations, but to futureproof customers’ investments. When we developed the TCS range, for example, every model was designed with these rules in mind, ensuring that efficiency, sustainability and regulatory compliance are built in from day one.”
Balancing regulation, cost and long-term sustainability
As both regulation and energy costs tighten, manufacturers are reassessing how they evaluate investment in cooling equipment.
“There’s definitely a shift happening,” Ferriday says. “Rising energy costs are now as much a driver as environmental policy, and both factors are forcing manufacturers to take a more strategic view of lifecycle performance. In
the past, capital cost often dominated decision-making. Now, energy use and total cost of ownership are increasingly important.”
He expects this focus to intensify as refrigerant options evolve. “We expect that trend to continue as F-Gas restrictions tighten further and as the next generation of ultra-low-GWP refrigerants becomes mainstream. At Atlas Copco, sustainability isn’t an add-on, it’s part of our core ethos, so our equipment and service models are evolving with that mindset.”
For manufacturers who might only replace a chiller once a decade or more, keeping pace with policy changes can be demanding. Ferriday says this is where suppliers have a wider role. “Regulatory change can be complex to navigate, especially for customers who might only purchase a chiller every 10 or 15 years. Our role is not just to design compliant equipment but to act as a long-term partner. We help customers understand the implications of new legislation and ensure they’re making informed, future-proof decisions.”
This support includes advising on new refrigerant technologies and efficiency upgrades. “That could mean advising when a new refrigerant technology becomes viable, or when upgraded control systems can deliver measurable efficiency gains. The goal is to prevent surprises, whether that’s a refrigerant no longer being available or a system falling short of new efficiency thresholds, and to support customers throughout the life of their equipment.”
SEPR and the importance of lifecycle efficiency
The introduction of the Seasonal Energy Performance Ratio (SEPR) has provided a more representative benchmark for energy efficiency in process cooling. Traditional measures such as the Energy Efficiency Ratio (EER) assess performance at a single, fixed operating point, which rarely reflects the varying conditions of real-world industrial use.
“Traditional metrics such as the Energy Efficiency Ratio (EER) measure efficiency at a single operating point, which doesn’t reflect the realities of industrial cooling,” Ferriday explains. “The Seasonal Energy Performance Ratio (SEPR) is far more representative because it accounts for variable loads and changing ambient conditions over the full year.”
He describes SEPR as an accessible way for customers to compare equipment performance: “It’s comparable to the energy rating label on a domestic appliance: it gives the user confidence that the system has been independently verified and benchmarked against defined conditions.”
With energy prices fluctuating and carbon targets becoming more visible, customers have become more analytical about running costs. “The last few years, with energy price volatility and increasing awareness of environmental impact, have accelerated that shift,” Ferriday says. “Customers are now far more focused on efficiency and carbon savings. Energy performance is no longer a ‘nice to have’; it’s a critical purchasing factor.”
He provides an example to illustrate the scale of potential savings. “Comparing a high-efficiency TCS260 A HT chiller with a SEPR of 6.03 against a conventional unit rated at 5.01 shows an annual saving of around 72,000 kWh – roughly £18,000 per year at current energy prices – and an emissions reduction of nearly 19 tonnes of CO?. Over a typical ten-year lifecycle, those savings equate to more than £160,000 and a significant environmental benefit.”
Expanding capability
Atlas Copco’s acquisition of Eurochiller in 2019 has had a lasting effect on its process cooling portfolio. “When Atlas Copco acquired Eurochiller in 2019, we gained not just a product portfolio but decades of expertise in process cooling,” says Ferriday. “Combining that with our heritage in compressed air has created a much broader ecosystem. We can now deliver integrated solutions across cooling, air, and gas, supported by shared service infrastructure and R&D.”
One of the main benefits has been in controls and connectivity. “The Elektronikon Mk5 controller used across our compressors is now standard on our chillers too, giving users the same intuitive interface and SMARTLINK connectivity. This consistency means customers can monitor both compressed air and cooling assets on the same platform, with shared diagnostic and performance data. It’s a simple but powerful advantage; especially for sites
running mixed utilities where downtime in one area can affect the whole production chain.”
Integration has also widened Atlas Copco’s reach into new markets. “Eurochiller was traditionally strongest in plastics, but Atlas Copco’s reach has opened up new opportunities in sectors such as food and beverage, pharmaceuticals and general manufacturing,” Ferriday says. “The product
portfolio has expanded accordingly – the TCS range now covers 110 kW to 610 kW and will be further complemented with larger models in
the future.”
The TCS range, he adds, demonstrates the value of combining design philosophies. “It’s modular, compact and engineered to deliver SEPR values consistently above 6, outperforming many competitors. Every element, from heat exchangers to control logic, reflects Atlas Copco’s engineering DNA, while the refrigerant and configuration options build on Eurochiller’s process know-how.”
The move towards low-GWP refrigerants
The F-Gas phase-down continues to reduce the availability of high-GWP refrigerants, making low-GWP alternatives such as R454B increasingly relevant. “R454B delivers comparable cooling capacity to R410A but with nearly 80% lower Global Warming Potential,” Ferriday says. “It performs very efficiently under partial loads, which supports higher SEPR values, and it’s well suited to industrial environments where stable performance and compliance are equally important.”
Transitioning to refrigerants with mild flammability ratings has required some adjustments. “The A2L classification means we’ve had to update safety protocols and training for service engineers – covering leak detection, handling procedures and risk assessment,” he explains. “In practice, R454B’s
flammability is extremely mild and well within safe parameters, but awareness and education are essential.”
The company has introduced training and documentation to ensure safe and consistent practices. “We’ve provided comprehensive training and documentation for our teams and partners to ensure consistent standards across the field. The transition has been smooth, and the environmental benefits far outweigh the additional precautions.”
Ferriday notes that many customers begin by focusing on compliance but soon recognise the operational benefits. “Initially, compliance tends to be the primary driver: no one wants to be caught out by changing regulations. But once customers understand the stability and efficiency benefits, they
increasingly view low-GWP refrigerants as a strategic investment.”
While R454B is part of a wider trend towards lower-impact systems, Ferriday sees it as a long-term option rather than a short-term measure. “Every refrigerant is part of a transition towards lower impact, but R454B is a very solid long-term solution. It offers low GWP, high efficiency and compliance longevity; so customers investing today can do so with confidence that their equipment will remain future-proof for many years.”
Connectivity, monitoring and predictive service
Connectivity is now integral to industrial equipment. “Connectivity is becoming the new standard,” says Ferriday. “With the Elektronikon Mk5 controller and SMARTLINK portal even smaller chillers under 150 kW can now provide real-time insights on performance, alarms and
energy use.”
This level of monitoring has practical advantages. “Simple temperature or pressure deviations can reveal a lot. For example, a compressor once sent a high-temperature warning that traced back to a delivery van blocking the ventilation intake – something easily missed without monitoring. By acting early, the customer avoided production loss worth thousands.”
The same approach is being applied to chillers. “By continuously monitoring parameters such as water temperature, refrigerant pressure and compressor load, we can identify early signs of imbalance or wear long before they cause a breakdown. It’s the difference between waiting for a fault and understanding when attention is due – much like maintaining a car based on how it’s actually driven rather than just relying on an MOT or annual service to fix issues.”
These insights are enabling a move from fixed-interval maintenance to data-led servicing. “It means maintenance can become genuinely proactive: engineers visit only when there’s a need, equipment runs more efficiently between services, and customers gain greater uptime with lower total cost of ownership.”
Looking further ahead, Ferriday sees the role of artificial intelligence increasing. “AI and machine learning will make it easier to interpret the vast amount of data these systems generate. Rather than manually analysing trends, AI can recognise subtle patterns – such as pressure fluctuations or temperature drifts – and predict likely issues. Over time, we envisage systems being able to learn the operating profile of each site and make recommendations automatically. It’s about turning data into foresight: identifying not just when maintenance is needed, but how to optimise performance continuously.”
As environmental expectations continue to evolve, process cooling design is being shaped by a combination of regulation, efficiency, and digital capability. For Ferriday, the direction of travel is clear: “Our guiding principle of ‘there’s always a better way’ means we treat compliance as a catalyst for innovation rather than an obstacle. The goal remains the same: to provide cooling solutions that meet industrial performance needs while being as kind to the planet as possible.