From Lab to Legislation: How Cresstec Became a Driving Force in National HVAC-R Performance Policy

Steve Becchio
Dec 5
3 min read

In 2019, after three years of rigorous internal testing at the Cresstec Pty Ltd HVAC-R Research and Development Testing Facility (CHRDTF), Cresstec engaged the CSIRO via its National HVAC Performance Testing Facility (NHPTF) to independently verify our findings around refrigerant charge optimisation in air conditioners.

Cresstec monitoring a screen, while outside the CEO stands in front of a building with a "CSIRO Energy Centre" sign.

That engagement ultimately led to a ground-breaking contribution to national policy and industry practice.

Why we initiated independent verification

Our internal data had repeatedly shown that many air conditioning units were operating far from optimum when refrigerant charge was even slightly off target, leading to degraded performance, greater energy consumption and higher emissions.

But to move from internal insight to industry benchmark, we needed independent validation under standardised test conditions.

CSIRO’s NHPTF offered just that.

Exterior of the National HVAC Performance CSIRO Test Facility, featuring open test rooms in blue and orange lighting, with visible equipment inside. — *Illustration of HVAC MEPS-style testing room (AI generated)*

However, because NHPTF was designed with the existing Minimum Energy Performance Standards (MEPS) framework in mind, there were limitations. The facility was only able to run static MEPS style tests, not full transient or fault dynamics testing.

So we agreed to focus the verification on the penalty of not having the correct refrigerant charge under MEPS T1 testing conditions.

What the testing revealed and why it mattered

When tested under those T1 conditions per MEPS, our data and CSIRO’s validation showed that incorrect refrigerant charge had significant consequences.

As a result of our successful collaboration, CSIRO asked for permission to forward our results to the Department of Climate Change, Energy, the Environment and Water (DCCEEW).

This was a world first because it involved independent bench-testing data from a government agency showing the real-world impacts of refrigerant charge faults.

Based on these results, DCCEEW announced a formal tender for a broader bench-testing program aimed at measuring the effects of preventable faults on air conditioners and refrigeration systems.

Selected were:

CSIRO for air conditioning
SuperCool Asia Pty Ltd for refrigeration and;
Cresstec as the industry expert with existing data and testing capacity.

The broader bench-testing project and what it proved

The project, now publicly released by DCCEEW, ran tests across a set of typical residential and light commercial RAC equipment.

Faults such as refrigerant undercharge or overcharge, blocked condensers or evaporators, contaminated refrigerant and other common faults were simulated with baseline and fault condition measurements taken to judge energy consumption, capacity loss and efficiency.

The results were stark.

Across most test scenarios, energy penalties ranged from roughly 14 percent to 20 percent compared to baseline.

In some cases, multiple faults combined to produce even higher penalties or risk of system failure.

For undercharged air conditioners, for example at 70 percent of correct refrigerant, capacity dropped significantly and affected both cooling and heating cycles.

These findings echo what earlier HVAC policy level studies identified as the most common faults causing energy and emissions penalties, especially refrigerant undercharge or leakage, along with poor maintenance practices.

What this means for HVAC policy and why Cresstec stands out

The 2019 CSIRO backed verification and our role in the broader DCCEEW bench-testing project marked a turning point for the Australian HVAC-R industry. Here is why:

We demonstrated convincingly that refrigerant charge is not a minor detail. It has measurable consequences for energy use, system performance and emissions under real-world MEPS equivalent conditions.

As one of only three selected organisations in the national bench test tender, Cresstec’s contribution highlighted our depth of expertise, long-standing data and commitment to rigorous testing.

The resulting public reports provide the industry with hard evidence that routine maintenance, including correct refrigerant charge, is essential for efficiency, reliability and reducing greenhouse gas emissions.

This shifts maintenance from being reactive or optional to preventive and strategic.

Cresstec: ahead of the curve and ready for what is next

At Cresstec, we believe real decarbonisation begins with real data. Our 2019 initiative from internal testing to CSIRO verified results laid the foundation for a national shift in how HVAC-R equipment is commissioned, maintained and regulated.

Today’s released bench-testing reports reflect the outcome of that early work. More than just validating the cost of neglect, they highlight the benefits of proactive care including optimised performance, lower energy bills, fewer emissions and greater longevity.

As the regulatory landscape tightens and demand for energy efficient, low emissions HVAC-R solutions continues to grow, Cresstec stands ready not just as a vendor but as a trusted industry partner. We do not simply deliver equipment. We deliver performance, compliance and sustainable outcomes.