5 Essential Factor To Your Freezer Design For Ultimate Efficiency

Designing an efficient freezer system involves more than lowering temperatures. By strategically planning around these five essential factors, you can boost energy efficiency, reduce maintenance, and ensure smooth operation.

1. Door Frame Heaters, Underfloor Heaters, and Ground Impact

To maintain structural integrity and efficiency, door frame heaters and underfloor heating are essential components in freezer environments.

• Door Frame Heaters: These heaters prevent ice buildup around door frames—an essential feature since each door opening exposes the freezer to moisture-laden air. Without them, ice accumulates, causing doors to stick and often leading to air leaks. This sticking, in turn, drives up energy use as the freezer works harder to maintain stable temperatures. Additionally, ice buildup damages seals, which increases maintenance costs.
• Underfloor Heaters: Particularly important for freezers on ground-level slabs, underfloor heaters prevent frost heave, a common issue in cold environments. When moisture in the ground freezes and expands, it creates structural shifts, leading to uneven floors and misaligned shelving. Therefore, underfloor heating stabilizes ground temperatures, protecting the floor structure and ensuring long-term durability.
• Impact of Inadequate Heating: Without these heating systems, freezers face issues like buckling floors, door malfunctions, and higher repair costs. Ignoring foundational heating elements ultimately leads to inefficiencies, greater energy demands, and increased wear over time.

2. Location: Ante Room or Coolroom Before Freezer

Strategic freezer placement near an ante room or coolroom reduces energy loss by limiting warm air entry.

• Buffer Zones: An ante room serves as a transition area between the freezer and outside environment. Thus, each time the freezer door opens, this buffer zone limits the entry of warm air, reducing internal temperature fluctuations. As a result, the refrigeration system runs more efficiently.
• Consistent Temperature Control: A buffer zone kept at moderate temperatures allows the refrigeration system to avoid constant adjustments in response to extreme warm air inflows. This setup, consequently, reduces temperature shocks, allowing the system to stabilise and save energy.
• Workflow Benefits: Especially in high-traffic environments, a buffer zone improves workflow by acting as a staging area for products entering and exiting the freezer. This approach minimises the time the freezer door remains open and reduces warm air infiltration.

3. Evaporator Placement and Managing Humidity Ingress

Proper evaporator placement and humidity control play essential roles in ensuring consistent temperatures and operational efficiency.

• Evaporator Placement: Positioning evaporators at the top of the freezer, spaced evenly, promotes even airflow and minimises temperature variation. Consistent air circulation prevents frost buildup in specific areas, ensuring uniform freezing conditions across stored items.
• Humidity Barriers: Each time a door opens, humid air enters, often leading to frost accumulation on walls and stored goods. Installing humidity barriers, such as air curtains or vestibules, can help limit moisture entry, protecting the system and maintaining operational efficiency.
• Enhanced Equipment Longevity: High humidity increases strain on refrigeration equipment, raising defrost cycles and wear. Therefore, controlling humidity and optimising evaporator placement enhances equipment longevity and reduces maintenance frequency.

4. Defrost Methods

Choosing the correct defrosting method impacts both energy efficiency and temperature stability. Each option offers distinct advantages depending on the freezer’s usage.

• Hot Gas Defrosting: Hot gas defrosting is particularly effective because it quickly circulates hot refrigerant gas through evaporator coils, melting ice buildup without significant temperature changes. This method is especially useful for high-use freezers, as it minimises downtime and allows systems to return to regular operation sooner.
• Electric Defrosting: Electric defrosting uses heaters in the evaporator coils to melt frost. Although it is less energy-efficient, this method is simpler to install and maintain, making it suitable for moderate-use systems.
• Optimised Defrost Cycle Frequency: Setting defrost intervals appropriately is crucial. Too-frequent cycles waste energy, while infrequent ones allow frost to accumulate excessively. Tailoring defrost frequency to match your freezer’s humidity level and traffic pattern ensures optimal energy use.

5. Door Management

Effective door management greatly reduces energy loss, as doors are high-traffic entry points that often let in warm air.

• Automated Door Closers: Automatic door closers prevent doors from being left open, limiting warm air entry and minimising temperature disruptions. This feature is particularly valuable in busy environments, where manual door management can vary.
• Motion Sensors and Alarms: Equipping doors with sensors or alarms helps ensure prompt closure, reducing human error. These tools help minimise door open time, preserving the freezer’s internal climate.
• Rapid Roll Doors: For high-traffic areas, rapid roll doors are ideal. By opening and closing within seconds, they minimise air exchange, keep temperatures stable, and reduce strain on refrigeration systems.

By addressing these factors during the design phase, you create a freezer system that is both energy-efficient and reliable. Proper attention to each element results in long-term savings on energy, maintenance, and operational costs, ultimately enhancing freezer performance.

Contact TIESA for Expert Freezer Design Solutions

For expert guidance on designing or optimising your freezer system, contact TIESA. Our team specialises in creating energy-smart, efficient refrigeration solutions tailored to your specific needs. We’re here to help your operations stay cool, reliable, and cost-effective. Reach out to discuss how we can support your project!

5 Essential Factor To Your Coolroom Design For Ultimate Efficiency

Coolroom Design requires more than selecting the right equipment. To achieve efficiency, regulatory compliance, and cost-effectiveness, focus on the following key factors during the design phase. Here are the five most important considerations, with actionable insights to ensure an optimal coolroom design.

1. Floor Insulation (Crucial for Preventing Condensation on Suspended Slabs)

In many cases, coolroom designs don’t always require floor insulation. However, its primary function is to prevent condensation on the underside of concrete slabs, particularly in suspended slabs. If not addressed, condensation can cause moisture damage, mold growth, and structural issues. Use at least 75mm thick expanded polystyrene (EPS) insulation as a thermal barrier for suspended slabs. Pair it with an electric floor heating system to prevent frost buildup. If your coolroom sits on solid ground, insulation may not be necessary, but it can still enhance energy efficiency.

2. Tundish Location (Optimise for Gravity Drainage)

Design your coolroom to allow drainage by gravity for optimal performance. Position the drain as close to the evaporator as possible. A nearby drain minimises the risk of blockages and promotes efficient water flow. If no drain is available, a condensate pump will be necessary, but it adds complexity and requires regular maintenance. Wherever possible, rely on gravity drainage to ensure long-term efficiency and easy maintenance.

Non-compliant designs with AS3500:2

AS3500:2 Compliant alternatives

3. Power Availability (Separate Circuits for Efficient Operation)

You need separate circuits for the coolroom controls and the condensing unit. A 1Ph 240V line supplies power to the coolroom’s fans, lighting, and control systems, drawing 10 amps. For larger coolrooms (with cooling capacities over 3000 watts), install a 3Ph 400V line to the condensing unit. This prevents overloading and improves system longevity by distributing the electrical load more effectively. Always consult an electrician to verify the site’s power capacity and ensure the system has the proper protection in place.

4. Product Load (Accurate Sizing for Cooling Systems)

Accurately calculating the product load is key to designing an efficient coolroom. The type and volume of products, along with turnover rates, will determine how much cooling you need. A general guideline is to allocate 100-150 watts per cubic meter. For example:

Case Study: Commercial Coolroom for Produce Storage

• Scenario: A food distribution company with a 180 cubic meter coolroom (10m x 6m x 3m) for fresh produce.
• Initial Load: At 100 watts per cubic meter, the required cooling capacity is 18 kW.
• Adjustment for Produce: Fresh produce increases the demand to 120 watts per cubic meter, totaling 21.6 kW.
• Adjusting for High Turnover: Frequent door openings increase the cooling requirement by another 10-15%, bringing the final cooling load to approximately 25 kW.

Proper product load calculations prevent undercooling or energy waste, ensuring that your coolroom operates efficiently even under peak demand.

5. Fire Rating of Panels (EPS, PIR, and XFLAM)

The fire resistance of your insulated panels significantly affects coolroom safety and compliance. Here’s how the three main options compare:

• EPS (Expanded Polystyrene): EPS is economical but highly combustible, making it less ideal for environments with strict fire safety regulations.
• PIR (Polyisocyanurate): PIR panels self-extinguish by charring, providing better fire safety than EPS. They are widely used in commercial coolrooms and meet many fire safety standards.
• XFLAM: XFLAM panels offer the highest level of fire protection. The FM Global-approved core prevents flame spread and produces minimal smoke, ensuring safety for both occupants and emergency responders. In addition to excellent fire resistance, XFLAM panels provide high structural stability and thermal efficiency.

For projects requiring high safety standards, particularly those insured by FM Global, PIR or XFLAM panels are essential choices.

Contact TIESA for Expert Coolroom Design Solutions

At TIESA, we specialise in creating custom-designed coolrooms that meet your specific needs. Whether you need guidance on insulation, power requirements, product load calculations, or selecting the right fire-rated panels, our team is here to help.

Contact us today to discuss your project and get expert advice on designing a coolroom that maximises efficiency, complies with safety standards, and meets your operational demands.

Refrigeration Service in Sydney with a Twist: Easy, Transparent, All About You

At TIESA, we believe refrigeration service in Sydney should always be simple and stress-free. That’s why we use Simpro to give you full control and insight into your systems. Here’s how this software enhances your experience.

Your Client Portal: Everything at Your Fingertips

Simpro’s client portal gives you instant access to all the details of your refrigeration systems. Rather than waiting for updates, you can log in anytime to monitor progress, approve quotes, and stay in control. This system allows you to track everything quickly and easily.

Track Your Assets, Avoid Surprises

With Simpro, you have real-time asset tracking, allowing you to see exactly when maintenance was done and what parts were replaced. This proactive tracking helps you avoid costly breakdowns, ensuring you stay ahead of potential issues. Additionally, it helps you plan future service needs.

Make Informed Decisions with Detailed Reports

Simpro’s detailed asset reports provide clear insights into equipment performance. These reports empower you to make informed decisions about scheduling maintenance and forecasting costs. Furthermore, they give you the ability to see patterns, enabling smarter planning and avoiding surprises down the line.

Communication Made Simple and Effective

Simpro streamlines communication between us and you. Rather than relying on scattered emails or missed phone calls, all approvals, updates, and feedback are centralized in one spot. Moreover, this efficient communication helps us respond faster, giving you peace of mind that nothing gets lost in the process.

Faster, More Efficient Service

By using Simpro, our team can deliver faster, more reliable service. You’ll receive real-time updates on job progress, and you’ll be notified immediately when a task is completed. As a result, you experience less downtime and better system performance, keeping your business running smoothly.

At TIESA, we’ve taken refrigeration service to the next level. With Simpro, we make the entire process easy, transparent, and efficient—giving you control and clarity every step of the way.

Experience the Twist Today!

Contact us today for a refrigeration service solution tailored to your specific needs