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.
