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Full-cycle industrial compressor replacement completed at a bakery in Gilroy without production downtime

Full-cycle industrial compressor replacement completed at a bakery in Gilroy without production downtime
bakery refrigeration restoration, commercial refrigeration repair Gilroy, ABC Service HVAC repair, rooftop condensers service, evaporator unit repair, TXV replacement, compressor replacement, refrigeration system cleaning, nitrogen purge service, deep vacuum refrigeration

Bakery — Refrigeration Restoration Project (Completed)

ABC Service

We recently completed a major commercial refrigeration restoration project for Bakery in Gilroy, CA. The facility operates two rooftop condensers connected to a total of six evaporator units. One of the systems was fully non-operational, and both required deep cleaning and component replacement due to contamination and moisture.

System Overview

  • 2 rooftop condensers
  • 6 evaporators (3 per system)
  • Left system: completely down
  • Right system: running, but with noise and performance issues
  • Findings: contamination, moisture, degraded oil, and failing TXVs and compressors

Work Completed

Step 1 — Full System Cleaning

We began with the non-operational left system:

  • Removed TXV
  • Performed a full chemical flush of the refrigeration circuit
  • Eliminated contaminants, moisture, and old mineral oil
  • Prepared lines for new components

Step 2 — TXV & Compressor Replacement

  • Installed a brand-new compressor
  • Installed a new TXV valve
  • Pulled a deep 24-hour vacuum to ensure the system was completely moisture-free

Step 3 — Vacuum Check, Nitrogen Purge, Refrigerant Charge

  • Verified vacuum hold
  • Performed nitrogen pressure test and purge
  • Charged the system with fresh refrigerant (provided by customer)
  • Completed startup and operational testing

The same multi-day process was repeated for the right system. If leaks were detected, additional diagnostic and repair time was performed as needed.

Project Goals

  • Restore full system functionality
  • Improve reliability and cooling performance
  • Protect equipment from oil contamination and moisture damage
  • Extend lifespan of both refrigeration systems through replacement of critical components

Cost Summary

Total labor cost: under $20K

Includes:

  • ✔ Full flushing of both systems
  • ✔ Compressor replacements
  • ✔ TXV replacements (all six units)
  • ✔ 24-hour vacuum
  • ✔ Nitrogen purge
  • ✔ System charging and startup

Materials (compressors, TXVs, refrigerant, chemicals) — not included in labor and billed separately.