Warehouse Cold Room Installation for Food Wholesaler - Client Case Study
Client:
Food Wholesaler
Location:
East Anglia
Project type:
Warehouse Cold Room Installation
Background:
Our client required a reliable warehouse cold room installation to support their expanding frozen food operation.
The project involved designing and installing a large-scale freezer within an existing warehouse, creating a high-performance cold storage solution capable of maintaining consistent temperatures in a demanding operational environment.
This cold room installation was designed to provide efficient, long-term frozen storage while supporting frequent access, large storage volumes and continuous forklift operations.
Client Requirements for Cold Storage Solution:
The client required a robust warehouse cold storage system to store a variety of frozen products, including fruit, meat and frozen chips.
Key requirements included:
- Maintaining a consistent -18°C storage temperature
- Supporting high daily pallet movement
- Installation within an unheated warehouse environment
- Allowing for frequent access during loading periods
- Safe operation with forklift truck (FLT) movement
- Efficient use of space with pallet racking systems
This required a high-capacity industrial cold room designed for both performance and operational efficiency.
Challenges:
The project presented several technical and operational challenges:
- High ambient conditions (up to 35°C), creating a significant temperature differential
- Frequent door openings, leading to increased heat gain through infiltration
- Installation within an existing warehouse, requiring integration with current structures
- Ensuring floor integrity, including prevention of frost heave
- Designing a system that supports continuous high-volume logistics
Our Solution:
We delivered a fully integrated cold room solution tailored to the client’s operational needs:
Cold Room Construction:
- Installed using 100mm insulated panels to ensure high thermal efficiency
- Designed to operate effectively within an ambient warehouse environment
Floor System:
- Constructed a new concrete floor slab over the existing floor
- Installed floor heater mats to prevent sub-floor freezing and structural damage
- Built a forklift-access ramp to ensure smooth and safe operations
Refrigeration System:
- Installed evaporators at high level (~5m) to maximise airflow distribution
- Positioned the condensing units externally, approximately 20–30 metres from the cold room, within a dedicated compound
- System designed to maintain stable temperatures despite frequent door openings and high product movement
Lighting & Electrical:
- Supplied and installed energy-efficient LED lighting
- Integrated microwave motion sensors controlling approximately 70% of lighting to reduce energy usage
- Installed emergency lighting within the cold room and above exits to ensure safety compliance
- Provided full controls and power supply for all lighting systems
Outcome:
The completed installation provides the client with a high-capacity, efficient and reliable frozen storage facility that supports their daily operations. The solution enables:
- Consistent -18°C storage conditions for product integrity
- Efficient handling of high daily pallet volumes
- Safe and effective forklift operation within the cold room
- Reduced energy consumption through smart lighting controls
- Long-term structural protection with a heated floor system
Conclusion:
This project demonstrates our ability to deliver large-scale, industrial cold storage solutions within complex operational environments. By combining strong technical design with practical installation expertise, we successfully transformed warehouse space into a high-performance freezer facility tailored to the client’s needs.