Cold room assembly

Cold room installation ensures efficiency, energy savings, and longevity. Whether you're renovating an existing space or starting from scratch, this step-by-step guide will walk you through the cold room installation process.

1. Initial Planning and Site Assessment

Before beginning the installation process, it is crucial to plan and evaluate your site. Consider the following:

AimDetermining what should be stored in cold storage — fresh produce, frozen produce, vaccines, etc.
Temperature rangeDetermine the ideal operating temperature. Cold rooms typically range from +15°C to -40°C.
Room sizeThis depends on the volume of goods, pallet racking systems, and space constraints.
WomenSuitable for indoor or outdoor use; proximity to loading ramps, power sources, and drainage systems.
Legal regulationsCheck compliance with local building regulations, food safety, and fire safety standards.

A detailed needs analysis will help determine the necessary equipment specifications and placement for optimum performance.

2. Design and Equipment Selection

After you have determined your requirements:

A. Layout Plan Design

Create a detailed floor plan. Include the following:

Door placement
Equipment placement
Shelf or storage positions
Airflow considerations

B. Equipment Selection

The main components are:

Insulated Panels (PUF, PIR or EPS)For walls, ceilings, and floors.
Cooling Unit: Split systems (remote condenser and evaporator) or monoblock systems
Cold Room Doors: Hinged or sliding; equipped with heating elements for freezers.
LightingMoisture-resistant LED lamps
Control SystemThermostats and remote monitoring devices

Choose energy-efficient and durable equipment approved for industrial use.

3. Site Preparation

Prepare the area to support the installation of the cold room:

A. Foundation

Ensure the floor is level and capable of supporting both the cold room structure and the weight of the stored products. If the cold room will be used in sub-zero temperatures, install vapor barriers to prevent condensation or swelling due to freezing.

B. Public Services

Arrangements must be made for electrical lines, drainage pipes, and condensate water management. Grounding systems must be installed for electrical safety.

C. Ventilation

Overheating should be prevented by ensuring adequate airflow around the condensing unit and through the ventilation ducts.

4. Installation of Insulated Panels

Begin constructing your cold room structure using prefabricated insulated panels:

A. Floor Panel Installation

If necessary, start with insulated floor panels. Pay attention to proper alignment, sealing, and load-bearing capacity.

B. Wall Panels

Connect the wall panels using cam-lock systems or interlocking joint methods.
Seal the joints with silicone or foam sealant to prevent air leaks.
Install the corner brackets for structural integrity.

C. Ceiling Panels

Securely mount the ceiling panels onto the wall panels. Depending on the size, you may need suspension systems or roof supports to bear the load.

D. Door Installation

Insert the door frame into the indicated opening. Note the following:

Proper sealing with gaskets
Smooth closing and locking mechanisms.
The door heaters (for the freezer compartments) are correctly connected.

5. Installation of the Cooling System

The cooling system is the heart of the cold room:

A. Positioning

To optimize air distribution, mount the evaporator unit high inside the cold room, usually on the ceiling or wall.
Install the condensate unit outdoors or in a well-ventilated mechanical room.

B. Connectors

Copper refrigerant piping should be used from the condenser unit to the evaporator unit.
Install insulated drainage lines to remove condensate water.
Use proper soldering techniques and pressure tests to ensure leak-free connections.

C. Electrical Installation

Connect the power supply to the condensation and evaporation units.
Install the thermostat and control systems.
Connect alarm or remote monitoring systems with cables if necessary.

All wiring must comply with local electrical safety regulations.

6. Leakage and Insulation Checks

After the building and cooling system are installed:

Seal all joints, screw holes, and passages with food-safe silicone.
Check the seals around the door to ensure an airtight seal.
Apply foam sealant to the corners, edges, and where the panels join.

Proper insulation prevents thermal bridges and reduces energy losses.

7. Testing and Commissioning

Before loading any products into the cold room:

A. Strengthening

Turn on the cooling system and wait for the cold room to reach the desired temperature.

B. Temperature Homogeneity Test

Use digital thermometers or thermal imaging devices to monitor hot spots or temperature variations within the room.

C. Leakage and Pressure Tests

Ensure there are no refrigerant or air leaks. Check drain lines and condensate systems.

D. Electrical Safety Checks

Ensure all electrical connections are secure and grounded. Verify that alarms, sensors, and control systems are functioning correctly.

Document all results as part of your commissioning report.

8. Shelf and Storage Layout

If the cold room is functioning correctly:

Install stainless steel or food-grade plastic shelves.
Ensure there is sufficient airflow between products and walls.
Label sections for easy inventory management.

Keep frequently used items near the door to minimize the risk of exposure upon entry.

9. Training and Security Protocols

Train your staff on the following:

Proper storage practices
Emergency procedures in case of system failure
Use of personal protective equipment (especially for cold storage facilities)
Secure entry and exit procedures

Install warning signs, emergency lighting, and evacuation mechanisms on the doors.

10. Maintenance and Routine Checks

To ensure long-term reliability:

Regularly check door seals and panel joints.
Clean the evaporator and condenser coils once a month.
Check the refrigerant levels and thermostat calibration.
Schedule professional maintenance every 6-12 months.

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Cold room assembly

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