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Custom Plug-In Monoblock Increases Merchandising Space, Reduces Noise and Energy Use in Ice Cream Vending Machines

An ice cream vending machine OEM replaced a traditional reciprocating compressor-based condensing unit with a modern bottom-mounted monoblock developed by Boyard. The new monoblock enabled the OEM to increase merchandising space by 23%, achieve energy savings of 17%, and significantly reduce noise levels and simplify unit installation.

Background

A vending machine manufacturer produces automated machines for a variety of merchandising purposes. One of their vending machines is designed to sell ice cream bars. These vending machines are installed either indoors or outdoors in high-traffic areas such as subway stations and tourist attractions. The required temperature range for the interior merchandising space of 0.8m³ in the machine is set between -10°C and -20°C.

Custom Plug In Monoblock Increases Merchandising Space Reduces Noise and Energy Use in Ice Cream Vending Machines 2

Challenges

The OEM’s original vending machine had a traditional condensing unit developed by another supplier, featuring a clunky compressor with a 22.4cc displacement. Although the power consumption of the unit was acceptable, the noise produced during operation was quite high, making it unsuitable for installation in quiet public spaces.

Additionally, the original condensing unit was large, taking up significant internal space in the vending machine. This limited the merchandising display and storage space for ice cream bars, resulting in higher restocking costs and preventing operators from displaying a wider variety of ice creams. The complex integration process of the condensing unit also forced the OEM to seek professional integration services.

The OEM decided to update the design of the vending machines with the following requirements:

  • Higher energy efficiency than the original system
  • More precise temperature control for the refrigeration compartment
  • Reduced integration and maintenance costs of the refrigeration unit
  • Increased merchandise display and storage space in the refrigeration compartment

Solution

To address these challenges, Boyard closely worked with the customer to fully understand their needs. Based on the limitations of the cabinet space and evaporator structure, Boyard redesigned the condenser and sheet metal parts. Boyard then proposed a bottom-mounted plug-in monoblock, a fully integrated compact refrigeration unit. As the unit was fully assembled and pre-charged at Boyard’s factory, the integration into the vending machine by the OEM was dramatically simplified compared to the original unit.

Custom Plug In Monoblock Increases Merchandising Space Reduces Noise and Energy Use in Ice Cream Vending Machines 3

Results

The proportion of the display space in the entire cabinet
The proportion of the display space in the entire cabinet

Increased Display Space

With Boyard’s compressor’s multi-application range capability and improved total system redesign, the monoblock is significantly more compact than the original unit. The new monoblock opened up more internal space in the machine, allowing the OEM to expand the merchandising display space by 23%.

Annual procuring and installation costs of the unit
Annual procuring and installation costs of the unit

Reduced Integration Time and Cost

Instead of procuring a clunky condensing unit and integrating it with other components in their vending machines, the OEM is saving significant time and cost by procuring a fully assembled, pre-charged monoblock from Boyard. The monoblock has all the key components, such as the condenser and evaporator, fully assembled as a single plug-in unit. This significantly reduces labor costs for integration and provides efficient and convenient service experiences.

Energy Savings

Boyard designed the monoblock using their own rotary compressor, which has been specifically designed and optimized for refrigeration over two decades. The COP of Boyard’s rotary compressor was 25% higher than the reciprocating compressor used in the original condensing unit. The advantage of a total system design utilizing high-quality components such as fans and evaporators made the monoblock highly energy-efficient, ultimately reducing energy consumption by 17%.

Noise Reduction

Using Boyard’s latest generation of refrigeration rotary compressors, the QXD-13K 4DN, for medium and low-temperature applications, the cooling capacity met the application requirements under the same testing conditions. During production, fan noise was reduced by replacing the axial flow motor and using silencing materials. These improvements significantly reduced the overall noise level of the vending machine.

Stable Temperature Control

Boyard has over 20 years of extensive experience in the production of rotary compressors for refrigeration. The outstanding cooling performance and stable temperature control of the compressors provide solid reliability for the refrigerated storage of ice cream.

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