HiPerForm Refrigeration System

The “Hi-Re-Li” system was developed in 1966 by Jim Harnish at Westinghouse as a groundbreaking advancement in refrigeration technology. Its innovative design enhanced energy efficiency and expanded the operational range of heat pumps, making them more effective in colder climates. Recognizing its potential, Paul Mueller Company later acquired the rights to the technology, incorporating it into their advanced cooling systems under the name HiPerForm.

Paul Mueller Company integrated its innovative principles into advanced cooling solutions. The HiPerForm system's use of subcooling regulation, flooded evaporator design, and adaptability to varying temperatures has made it a standout technology in efficient and reliable refrigeration.

Subcooling-Regulated Expansion Device

The HiPerForm system introduced a significant shift in how refrigerant flow is regulated. Instead of using the superheated vapor exiting the evaporator, the expansion device adjusts based on liquid subcooling exiting the condenser.

What does this mean?

In most traditional systems, expansion devices regulate refrigerant flow based on superheat, which is the temperature above the refrigerant's boiling point. This ensures no liquid enters the compressor, which could cause damage.

HiPerForm uses subcooling—where the refrigerant is cooled below its condensation temperature—as the regulating factor. This ensures the refrigerant entering the evaporator is stable and sufficiently cooled for optimal performance.

Why this matters:

Subcooling-based regulation enhances efficiency, stabilizes refrigerant flow, and maximizes the evaporator's heat exchange capacity, making for more efficient use of the evaporator by flooding it with liquid refrigerant.

Enhanced Liquid Subcooling

The HiPerForm system employs innovative techniques to further cool the liquid refrigerant:

• EC Fan motor for precise head pressure control in low ambient conditions
• A specially designed suction accumulator with integrated heat exchange capabilities provides further subcooling and protects the compressor by supplying it with cold refrigerant vapor.

Flooded Evaporator Design

The evaporator in the HiPerForm system is designed to operate in a flooded state, meaning it is intentionally filled with saturated liquid refrigerant to maximize the surface area available for heat transfer.

The suction accumulator ensures that any liquid refrigerant is separated before reaching the compressor, protecting the system while maintaining high efficiency.

Adaptability to Ambient Conditions

HiPerForm systems operate efficiently across a wide range of temperatures, even in extreme cold, without requiring complex head pressure controls. This adaptability makes them suitable for a wide range of conditions and integrates well with our Fre-Heater® heat recovery system.

Plug-and-Play Setup

Additionally, The Electronic Valve Control (EVC) board simplifies system setup with plug-and-play functionality, allowing necessary tuning and adjustments to be done within the board for seamless operation.

Higher Efficiency

Subcooling-based regulation reduces energy consumption while optimizing refrigerant flow. The more efficient use of the evaporator allows us to make cooler product temperatures without making ice.

A series of tests performed by TNO  in 2014 compared the performance of two condensing units with a Mueller O-1250 milk cooling tank. The tests measured energy consumption and cooling time for two scenarios: cooling 1/6 of the tank capacity (847.5L) and the full tank capacity (5,085L).

Results

Paul Mueller Company’s E-Star® Condensing Unit Utilizing HiPerForm

• 1/6 Tank: 6.370 kWh (1hr 21min) → 7.516 kWh/1000L
• Full Tank: 7.466 kWh (1hr 41min) → 8.809 kWh/1000L

Competitor’s 5-Horsepower Condensing Unit 

• 1/6 Tank: 7.030 kWh (1hr 37min) → 8.295 kWh/1000L
• Full Tank: 7.690 kWh (1hr 48min) → 9.074 kWh/1000L

Key Takeaways

• The E-Star cools faster, saving 16 minutes for 1/6 capacity and 7 minutes for full capacity.
• The E-Star is more energy-efficient, using 9.4% less energy for 1/6 capacity and 2.9% less energy for full capacity.

Reliability

The system is engineered to minimize risks to the compressor, safeguarding it from potential damage and ensuring reliable, consistent performance under a wide range of operating conditions. This robust design helps to maximize uptime and efficiency, even in challenging environments, reducing the likelihood of disruptions or costly repairs.

Our commitment to reliability extends beyond the system itself. It is fully supported by our dedicated service team, which provides expert guidance and swift assistance to promote exceptional performance and long-term value.

Versatility

Its ability to function in extreme temperatures makes HiPerForm ideal for both refrigeration and heating.

Improved Refrigerant Utilization

Flooded evaporator design and enhanced subcooling ensure maximum heat transfer efficiency. The HiPerForm system can reduce the required refrigerant charge by up to 40% compared to direct expansion systems.