Ensuring always-on cold chain operations in Singapore

The facility had relied on a single, centralized refrigeration system for more than 25 years. Ageing equipment, declining insulation performance, and the absence of system redundanc posed significant operational risks. A single failure could disrupt the entire cold chain.

At the same time, the facility operates around the clock and plays a critical role in Singapore’s food supply, in a country where more than 90% of food is imported. Any downtime would have direct implications for food availability and safety.

The challenge was further compounded by evolving regulatory requirements. In line with Singapore’s Green Plan 2030, the facility needed to transition away from hydrofluorocarbon (HFC)-based systems toward more sustainable, low-impact alternatives, without interrupting day-to-day operations.

The facility partnered with Johnson Controls to deliver an end-to-end refrigeration upgrade, replacing legacy systems while maintaining continuous operations.

The upgrade was executed through a carefully planned, five-year phased approach. Precision sequencing allowed individual systems to be replaced incrementally, aligned with cold room usage cycles, ensuring uninterrupted service throughout the transformation.

As part of the solution, the facility transitioned from HFC-based refrigerants to ammonia, selected for its high efficiency and zero ozone depletion and global warming potential. Safety and resilience were enhanced through built-in redundancies, ammonia detection alarms, and real-time monitoring systems.

This approach enabled the facility to move from a single-point legacy system to a more robust, future-ready refrigeration infrastructure.

Through a carefully phased retrofit, the facility replaced its ageing refrigeration infrastructure without disrupting round-the-clock operations. This transfomration strengthened resilience, improving safety, and aligned the facility with Singapore’s long-term sustainability and food security objectives.

Key outcomes include:

• 24/7 continuous operations maintained throughout a complex, five-year retrofit program, avoiding disruption to critical cold chain activities.
• More than 300 individual cold rooms supported by upgraded, modern refrigeration infrastructure.
• Reduced operational risk by eliminating reliance on a single, ageing refrigeration system and introducing built-in redundancy.
• Improved safety and operational visibility through ammonia detection alarms and real-time monitoring systems.
• Lower environmental impact with zero-GWP, zero-ODP refrigerant.
• Alignment with national sustainability goals, supporting Singapore’s Green Plan 2030, Green Mark standards, and long-term food resilience objectives.

As a result, the facility now operates as one of Singapore’s most advanced cold chain hubs, with infrastructure designed to support future demand while contributing to national food security and sustainability goals.