Why Ammonia Is Essential in Food Plants — and Where Most Risks Really Come From 2026-01-15

Ammonia leaks in food facilities tend to make headlines quickly — including a recent Rhode Island incident that hospitalized 13 people after a rooftop ammonia release, as reported by People.com. Read the full article here: https://people.com/13-hospitalized-2-critical-ammonia-leak-taylor-farms-rhode-island-11854328

Stories like this can sound alarming to the general public. Inside the food industry, however, ammonia itself is not unusual at all. In fact, it is one of the most widely used and effective tools in large-scale food production.

The more important question isn’t why ammonia is used — it’s where risk tends to develop over time, even in well-run facilities.

Why Ammonia Is So Common in Food Facilities

It’s the backbone of industrial refrigeration. Most large food plants rely on ammonia because it transfers heat extremely well. It is used to cool produce, meat, dairy, prepared foods, blast freezers, and large cold-storage areas. A single central ammonia system can reliably serve multiple temperature zones far more efficiently than dozens of smaller systems.

It’s energy-efficient and cost-effective. For facilities that operate 24/7, refrigeration efficiency directly affects operating costs. Well-maintained ammonia systems can remain efficient for decades and significantly reduce long-term energy use.

It’s environmentally responsible. Ammonia has zero ozone depletion potential and near-zero global warming impact. As many synthetic refrigerants are phased down, ammonia remains one of the most sustainable long-term options available.

If Ammonia Works So Well, Why Do Incidents Still Happen?

The Rhode Island incident reflects patterns seen across the industry. Most ammonia events are not caused by a single catastrophic failure, but by a combination of smaller, often predictable factors.

Hard-to-reach locations. Leaks frequently originate in rooftop condensers, elevated piping, or remote valve stations — areas that are physically harder to inspect. In the Rhode Island case, emergency officials reported that the leak occurred on the roof, allowing vapor to migrate downward before shutdown.

Aging equipment that “has always worked.” Ammonia systems often evolve over decades. Continuous operation increases vibration fatigue, seal wear, corrosion, and thermal stress. Components that appear fine can fail once they pass their intended service life.

Incremental changes that reduce visibility. Expansions and retrofits can unintentionally create blind spots. Piping gets longer, access becomes tighter, and drawings don’t always reflect the system as it exists today.

Peripheral systems that receive less attention. Core equipment is usually well monitored. Edge systems — rooftop piping, dock coolers, and remote evaporators — are more likely to be overlooked, even though failures often start there.

Emergency plans that lag behind reality. Staffing, layouts, and procedures change. A response plan that worked years ago may not align with today’s operations, especially during shift changes or off-hours.

Practical Questions That Help Reduce Risk.

Without overhauling an entire system, facility teams can reduce surprises by asking: • Are hard-to-access components inspected as consistently as central equipment? • Are any parts operating beyond their expected service life? • Have expansions changed airflow, access, or exposure risk? • Do drawings reflect the system as it exists today? • Does the emergency plan match current staffing and layout?

A Final Thought

Ammonia is safe when handled with respect. It remains one of the most efficient, reliable, and sustainable refrigeration options in the food industry. Most incidents don’t come from one major mistake. They come from small factors aligning at the wrong moment — an aging valve, a hard-to-reach location, a layout change, or a gap in visibility.

Our work at Farrell Partnership frequently involves helping facilities evaluate how refrigeration systems evolve as plants grow and change. When design, maintenance, and long-term planning stay aligned, teams are better positioned to identify emerging risks early — before small issues have the chance to become operational or safety events.