We Were Tracking Refrigerant Leaks Before Net Zero Was a Buzzword - Refrigerant Management & Leaks Detection

"Our early refrigerant gas leak testing helped trigger a wider CSIRO study into HVAC performance. The results reshaped how refrigerant leak detection and loss is understood, and what to do about it."

Revolutionizing HVAC Performance: The Impact of Refrigerant Leak Testing

If you manage or own commercial HVAC systems and plant, you already know the pain points.

• Rising energy costs.

• Unplanned downtime and expensive emergency callouts.

• Complaints about comfort.

• New regulations demanding emissions tracking and leak reporting.

  
  

Here’s the point: if your system is quietly leaking refrigerant, you’re losing money, efficiency, and compliance ground every day, and you probably don’t even know it. That "topping up" during routine service could be masking a leak that’s driving up your bills and undermining your sustainability goals.

The Genesis of REED: A Game Changer in HVAC

REED (Regulated Efficiency & Emissions Device) has been up and running since 2016, motivated by a desire to tackle the hidden problems that make HVAC systems less efficient and more costly to run. Its job is simple: to remove pressure in the system when not needed, so the compressor motor doesn't need to work as hard.

We’ve tested it in our own lab and saw just how quickly performance issues dropped when refrigerant levels weren’t right for the conditions. That work was carried out at the Cresstec HVAC-R Research & Development Testing Facility (CHRDTF), globally unique in its ability to measure how HVAC systems behave under real, changing conditions.

Unlike most facilities that only test steady-state performance, ours captures data every half-second, showing what really happens as systems start, stop, and adjust to load. We proved how even small changes in refrigerant levels quietly drain efficiency and drive up energy costs over time.

CSIRO Verification: The Turning Point for Refrigerant Leak Detection

To validate our findings, we sent an early version of REED to the CSIRO for independent testing. They ran it under standard “T1 MEPS” conditions—27°C inside and 35°C outside—and confirmed what we were already seeing.

Incorrect refrigerant charge levels waste significant amounts of energy. The results were strong enough that CSIRO shared them with the Department of Environment. This helped spark a wider study into common HVAC faults, and we were invited by the department to contribute our own data as industry experts.

Key Insights from the CSIRO Collaboration

When we tested systems under standard government-rated conditions, known as T1 MEPS (Minimum Energy Performance Standards), we confirmed that running low on refrigerant can seriously reduce performance.

• At 70 percent of the recommended charge, cooling output dropped by about 25 percent.

• Dropping to 50 percent of the recommended refrigerant charge means the system keeps using electricity but delivers very little cooling. You’re paying for power without the comfort.

  
  

But here's the twist: those results only apply when the system is working flat out. In part-load conditions, like cooler months, being slightly undercharged can actually help efficiency. That’s the thinking behind REED. Instead of holding a fixed amount of refrigerant, it adjusts automatically based on what the system needs at that moment.

The key lesson? Refrigerant levels shouldn’t be one-size-fits-all; they should change as conditions change. Yes, leaks are a problem. But the real win is ensuring your system always has just the right amount of refrigerant to work at its best. In fact, leak detection came naturally from that.

Because we can move and measure refrigerant in tiny amounts, we can spot even the smallest leaks—sometimes just a few grams—while keeping performance perfectly tuned.

The Evolution of REED: From Concept to Real-World Application

The CSIRO study didn’t change the core of what REED did; it confirmed it. What it gave us was independent validation and real-world proof that our approach worked—not just in our lab, but in a live building with real energy bills.

From there, we fine-tuned how REED is installed, how it integrates with different systems, and how it reports performance data. We also used what we learned to improve how REED responds in part-load conditions. Those times when the system isn’t running flat out but still needs to stay efficient.

REED is still based on the same idea we had in 2016: keep refrigerant levels exactly where they need to be, all the time. The difference now is it’s smarter, more reliable, and easier to implement than ever before.

The 2023 to 2024 CSIRO Study: A New Benchmark

In mid-2023, we installed REED in a government office building in Richmond, NSW, and asked CSIRO to independently verify its impact in the real world.

Their Measurement and Verification (M&V) study compared the system’s energy performance before and after REED went live.

Over 15 months, REED delivered:

• 35 percent energy savings compared to baseline performance.

• 10.5 megawatt-hours of electricity saved.

• 8.3 tonnes of CO2e emissions avoided.

  
  

CSIRO followed international M&V standards (ASHRAE Guideline 14, IPMVP Option B) using actual sub-metered data. They didn’t touch the system; they didn’t modify our install. They just measured the numbers, and the numbers held up.

Lessons Learned from Real-World Implementation

Controlled refrigerant optimisation doesn’t just work in theory. It works in commercial environments, under real loads, across seasons.

The Bigger Picture: Why This Matters Now

From July 2025, Australia starts cutting back on which refrigerants can be used, starting with smaller systems, but big commercial setups won’t be far behind. Older refrigerants like R-410A and R-134a are being phased down by 85% by 2036.

That means they’ll get harder to find, more expensive to top up, and eventually be off the table as options. REED helps you deal with that now. It keeps your current systems running more efficiently, using less refrigerant and holding onto it longer.

That means fewer costly top-ups, less waste, and more time before you need to switch systems. Meanwhile, facilities face increasing pressure to report their emissions and energy performance. Leaking refrigerant systems are no longer just inefficient; they’re non-compliant.

With REED, you're not only avoiding costly refrigerant loss. You're ahead of the curve on energy use, emissions, and reporting. You're not scrambling to meet the new standards; you're showing up with results and documentation.

What We Know Now: Key Takeaways Since 2016

Since 2016, we’ve learned:

• Minor leaks cause major energy loss.

• Fixed refrigerant charges are outdated for modern efficiency demands.

• Dynamic refrigerant control saves energy, extends equipment life, and reduces emissions.

• Data matters; measurement and verification validate savings and build confidence.

  
  

The Benefits Stack Up: Why Choose REED?

Here’s what REED gives you:

• Energy savings: We’re talking about a 35 percent drop in HVAC energy use, which means less money spent on electricity every month.

• Lower emissions: Refrigerant gases are powerful pollutants. Catching leaks early and keeping the system running efficiently means fewer harmful gases released into the air.

• Better compliance: As laws change, you’ll need to report your energy use and refrigerant emissions. REED helps track and reduce both, so you’re not caught off guard.

• Longer system life: When your system isn’t overworked from poor refrigerant levels, it lasts longer. That means fewer breakdowns and fewer expensive replacements.

• Predictive maintenance: REED helps spot issues early so they can be fixed before they cause downtime. That means fewer surprise failures, more planned maintenance, and lower repair costs.

• Fewer surprises: REED doesn’t just wait for something to go wrong. It monitors your system in real time, flagging small issues before they become big problems.

  
  

Looking Ahead: The Future of HVAC-R Systems

This is no longer just about sustainability targets. It’s about cost control, equipment longevity, and staying compliant with a changing regulatory environment. Cresstec’s work with CSIRO didn’t just prove a point; it verified a concept proven in our lab dating back to 2016, culminating in real-world results by 2024.

Want to Dig Deeper?

Find out how your site stacks up. Learn more at Cresstec.com or schedule your tailored savings audit today.

References

1. CSIRO (2024). Measurement & Verification Analysis of REED Installation: Cresstec Kickstart Project. Independent report confirming REED delivered 35% energy savings and cut over 8 tonnes of emissions in a live government building.

2. IPMVP Core Concepts (2022). The international standard CSIRO used to measure and verify energy savings, ensuring the results are credible and repeatable.

3. ASHRAE Guideline 14-2014. Framework used for statistical analysis and uncertainty in the CSIRO study, setting the benchmark for energy performance validation.

4. Department of Climate Change, Energy, the Environment and Water (2023). New rules for cleaner cooling from July 2025. Outlines regulatory changes affecting refrigerant types, equipment restrictions, and emissions reporting obligations.

5. AIRAH (2025). HVAC&R and Refrigerant Emissions in the Built Environment. Industry insights showing why refrigerant leakage is now a compliance and emissions concern.

6. Cresstec (2024). REED Technology Overview and Applications. Internal product documentation explaining how REED works and where it fits into modern HVAC operations.