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Cold Room Design Essentials

The design of cold storage rooms is influenced by various factors including temperature requirements, room volume, insulation, and cooling equipment. Different products necessitate specific temperature settings, and the insulation must balance cost and efficiency. Key components such as evaporators, temperature sensors, humidification systems, and air circulation are essential for maintaining product quality and safety in cold storage environments.

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60 views5 pages

Cold Room Design Essentials

The design of cold storage rooms is influenced by various factors including temperature requirements, room volume, insulation, and cooling equipment. Different products necessitate specific temperature settings, and the insulation must balance cost and efficiency. Key components such as evaporators, temperature sensors, humidification systems, and air circulation are essential for maintaining product quality and safety in cold storage environments.

Uploaded by

yasser zedan
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd

Cold room design

The design of cold storage rooms varies a lot. The exact design depends on many aspects. Before
a new room is built, many questions have to be answered. An important one is what temperature
the room should be able to reach? Which cooling equipment is needed then? Should the room be
suitable to cool down products that come in at high field temperature? It is interesting and useful
to recognize the different elements of the cold room and know the reasoning behind it.

Directly to
Temperature requirementRoom volumeInsulationDoor and
windowEvaporatorTemperature sensorsHumidification systemAir circulation
and ventilation

Different fresh products on display


Temperature requirement
Different commodities need different temperatures. In some cases, the desired temperature of
fresh products can even be below 0 degrees C, such as long storage of pears. Room insulation
and cooling capacity (cooling equipment) are designed according to the requirements of the
specific product. It is also important to know whether the function of the room is to store product
that is already at low temperature, or whether it must have the possibility to cool the product
from warm (field) temperature to lower storage temperature.

Cold rooms come in all sizes and various temperature ranges.


Room volume
Cold rooms come in all sizes. Rooms with smaller volumes in the range of a few hundred m3 are
the most common. Five rooms of 200 m3 give more flexibility in the choice of temperature than
1 room of 1000 m3. Most companies have rooms with various temperature differences. On the
other hand, the more rooms, the more insulation panels, refrigeration units and accessories are
needed.

Insulated door of a cold room.


Insulation
The purpose of insulation of storage rooms is to minimize heat transmission through walls, floor
and ceiling. PUR/PIR (polyurethane, polyisocyanurate) sandwich panels are nowadays usually
chosen for wall insulation. A thicker insulation gives a higher insulation value. The choice of
insulation thickness is based on a compromise between costs of the insulation panels, loss of
useful store volume, energy consumption by the cooling system and impact of reduced heat load
on product quality. Insulation usually requires little or no maintenance. Insulation panels can be
easily cleaned with soap and water. When using a high-pressure cleaner, make sure that you do
not damage a gas-tight finish or sealant.

Cold store doors with window.


Door and window
The room door is also made of insulated material. It must close tightly, so damage and dirt (on
the rubber seals) should be avoided. There are several types of doors, some open sideways and
others open vertically. Some must be opened by hand; others can be operated electrically. It is
important to monitor the quality of the product during storage. Therefore, Controlled
Atmosphere rooms can have special control windows. These are locked for safety. Under CA
conditions, these should only be opened under strict safety guidelines.

Evaporators in a cold room.


Evaporator
The function of the evaporator is to remove heat from the room. In summary, its function can be
described as follows. A liquid refrigerant enters the evaporator on one side via a pipe system. On
the other side it leaves the evaporator (partly) as a gas through pipes. The pipes are connected to
the rest of the refrigeration system that is located outside the room. This evaporation proces takes
place under low pressure. The evaporation of the refrigerant causes a low temperature of the
evaporator coils. Fans guide air from the room over the coils so that the air leaving the
evaporator will be colder than the air entering the evaporator. Depending on the need for cooling,
the evaporator is switched on and off. The evaporator coils can become so cold that ice can form
on them. In that case, there is a regular (automatic) defrosting.

Calibrating temperature sensors


Temperature sensors
A number of temperature sensors can be found in a storage room. It must contain at least a
control sensor, product sensors and often the defrost sensor. A control sensor is available in each
storage room to measure the air temperature at a fixed position. This sensor is usually placed in
the air flow on the suction side of the evaporator. It is used to control the on/off cycles of the
cooling. Product sensors are strongly recommended at least in the coldest position and in the
warmest position in the room. Another sensor is the defrost sensor that is located near the
evaporator coils. It is used to control the defrosting action. This sensor measures the coil
temperature. When the coil is ice-free (above 0 °C), the defrosting can be stopped.

Humidifier.
Humidification system
Storage rooms can be equipped with humidification systems for the quality of fresh products if
necessary. Different types of humidification systems are being used. Ultrasonic systems are
placed outside the room. They produce a fine mist. This fog is brought into the room via a tube
or piping system. These systems usually bring the fog to the front of the evaporator. During
operation, the evaporator fans blow the mist into the room. Another group of humidification
systems make use of nozzles. These nozzle humidification systems often have a central pump in
the storage facility and a valve per room. One or more nozzles are then placed near the outgoing
air flow of the evaporator.

Close up of ventilator.
Air circulation and ventilation
Fans perform the task of air circulation in the room. Air circulation is necessary to limit
temperature differences between parts of the room. The fans can be found at the back or
frontside of the evaporator and sometimes there are additional fans present in the room. Besides
air circulation, ventilation is important. Ventilation refers to the exchange with air from outside
the room. Doors which are (partly) open and windows contribute to ventilation. Also, fans for
ventilation may be found in walls or ceiling. When workers are present in cold rooms, this air
exchange is necessary to maintain a healthy and safe environment. Controlled Atmosphere
rooms, which are closed to workers, are often equipped with automatic aeration. If the oxygen
level in the room becomes too low, ambient air enters the room via valves in a controlled
manner.

Common questions

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The primary design considerations include temperature requirements, room volume, insulation, door and window configuration, evaporator placement, and temperature sensors. Each element addresses specific functional needs. Temperature requirements are crucial as different commodities need specific storage temperatures to maintain quality, with some requiring temperatures below 0°C . Room volume is important for flexibility; smaller rooms allow varied temperature settings, enhancing storage options . Insulation minimizes heat transmission and is a balance of cost, storage volume, and energy efficiency . Proper doors and windows ensure a controlled environment by preventing heat entry . Evaporators remove heat, crucial for maintaining low temperatures . Temperature sensors provide control over climate conditions within the room, essential for product safety .

Managing a multi-use cold room involves balancing the specific requirements of different products regarding temperature and humidity. Different commodities need diverse settings; some might require temperatures below 0°C, while others thrive at higher levels. Humidity levels must be tailored to prevent spoilage. Hence, the system must be flexible yet precise, requiring advanced controls and possibly separate zones within the room, complicating design and increasing cost .

Ventilation and air circulation are vital for maintaining uniform temperatures and ensuring safety when workers are present. Air circulation minimizes temperature gradients by distributing air evenly, while ventilation refreshes the air, essential for safety in controlled atmosphere rooms to prevent low oxygen levels. This air exchange is also critical to maintaining a safe work environment, providing necessary oxygen levels .

Doors and windows in cold rooms must be insulated and tightly sealed to maintain thermal efficiency by preventing heat entry. Design choices, such as door type (manual or electric, sideways or vertical opening) and quality seals, directly influence heat transfer rates. Control windows in Controlled Atmosphere rooms must provide easy monitoring while ensuring safety and minimal thermal loss .

Temperature sensors, including control, product, and defrost sensors, provide vital data for regulating cold room conditions. Control sensors manage cooling cycles, product sensors verify temperature uniformity at critical points, and defrost sensors ensure ice-free evaporator coils for optimal function. This systemized monitoring enables precise climate control, preserving product quality and reducing energy use .

Having multiple smaller cold storage rooms allows for greater flexibility in storage management. This configuration supports different temperature settings per room, accommodating diverse commodities' needs. It also mitigates risk; if one room fails, others remain operational. However, this setup requires more insulation panels and refrigeration units, which may increase initial costs .

Defrost sensors, placed near evaporator coils, determine the presence of ice. By measuring the coil temperature, they control when defrosting should occur, preventing ice build-up which can reduce cooling efficiency by blocking airflow. Effective defrosting keeps coils at optimal temperatures, improving energy use and maintaining consistent cooling .

Humidification systems are integral to maintaining optimal moisture levels, preventing dehydration, and preserving the quality of fresh products. Systems like ultrasonic and nozzle humidifiers introduce moisture without excessively wetting surfaces. This capability is vital for products sensitive to low humidity, ensuring freshness and extending shelf life .

Insulation material and thickness are crucial in minimizing heat transmission and improving energy efficiency. Polyurethane or polyisocyanurate panels are typically used for their high insulation value. The thickness must balance cost, energy consumption, and storage volume. Thicker insulation reduces energy loss and strengthens temperature control, which is essential for maintaining product quality at lower energy costs .

The evaporator is key to a cold room's cooling system. It removes heat by circulating a refrigerant that enters as a liquid and exits (partly) as gas, undergoing a low-pressure evaporation process. This creates low temperatures on the evaporator coils, which cool the air passing over them. The efficiency is determined by the evaporator's ability to maintain low coil temperatures and manage defrosting cycles to prevent ice formation, which can impair performance .

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