How much area is required for cold storage?

The cold storage industry market in the United States is a big one — reaching a value of $33.08 billion in 2022 alone. From food supply to cosmetics, it’s more than safe to say that having a cold storage warehouse is essential to so many businesses as they preserve perishable items that would otherwise go to waste.

Get started on your acquiring a cold storage warehouse.

But first, get informed below.

In this article, we’ll cover everything you need to know about cold storage warehouses so you can make a more informed decision about which cold storage warehouse system is best for your business’s needs.

Cold Storage Warehousing 101

Cold storage warehousing refers to the storing of perishable and sensitive items at a specific temperature to maintain their shelf-life, quality, and integrity. This would include (but isn’t limited to):

• Food (frozen food and non-frozen food)
• Medicines
• Artwork
• Cosmetics
• Plants
• Film
• Candles

You can probably guess how cold storage warehousing works, as they’re essentially giant refrigerators that double as a storage space. Put simply, cold storage warehouses work to maintain cooler temperatures via a combination of HVAC cooling systems and insulation. 

While the insulation serves the same purpose as it does in the home — to limit the transfer of heat between the inside and outside — the cooling part is much more complex. It takes a combination of coolant, pipes, radiators, and fans to mitigate heat by replacing it with cool air.

Here’s the breakdown:

• The coolant — or refrigerant — acts as the lifeblood of the system. It’s made from anhydrous ammonia, and it circulates throughout a series of tubing, pipes, and other components.
• The compressor is the primary component in the cooling system. It’s responsible for raising the pressure of the coolant as well as the temperature through consistent compressions that pump the coolant into the condenser.
• The condenser works to remove heat from the coolant using tubing, fans, and sometimes a water spray. During this process, the coolant changes its state from a gas to a liquid and then flowers into the receiver.
• The receiver stores the high-pressure liquid condensate that comes from the condenser. This is how the receiver maintains the whole system’s pressure while acting as a buffer for times when increased loads come through, such as when more cool air is required. The receiver uses an expansive valve to regulate this pressure, as well as the temperature and the amount of coolant released into the separator.
• The separator receives and contains the coolant from the receiver. There are pumps outside of the separator that pull the coolant into another expansion valve, where the flow rate gets adjusted before it can enter the evaporator. These same pumps also work to adjust the load placed on the evaporator, which is determined by the overall cooling needs within the warehouse.
• The evaporator is responsible for bringing cold air into the space and lowering the temperature. It works by passing the already cold coolant through a series of tubes that have fans blowing air over them to absorb and release any additional heat. In turn, the air cools the evaporator to chill the space and maintain the goods within it.
• The process repeats itself on a continuous cycle to maintain temperatures ranging from -122.8°F to 70°F, depending on the business’s needs.

Who Needs a Cold Storage Warehouse?

There are different types of cold storage warehouse options, and these options are essential to a wide range of businesses that store and sell time-sensitive goods. Some of the more specific industries that utilize cold storage include:

• Restaurants and food outlets
• Grocery stores
• Food services firms
• Frozen food producers
• Importers and exporters
• Agricultural producers
• Pharmaceuticals 
• Healthcare institutions
• Cosmetic companies
• Skincare companies

Ultimately, if you run a business that depends on the sales or storage of perishable or temperature-sensitive items, you’ll need a cold storage warehouse for those items.

The Different Types of Cold Storage Warehouse Options

There are several different types of cold storage warehouses you can choose from, and they primarily differ in size and level of refrigeration. They can also be broken down into private and public cold storage.

Let’s start with the difference between public and private cold storage warehousing:

• Private cold storage is characterized as being owned by the same enterprise. Whatever products or goods the enterprise in question offers will be kept in the same cold storage facility. It’s common for private cold storage warehouses to be connected to the primary manufacturing facility to maintain optimal quality and freshness as well as to reduce costs. Of course, private storage warehousing is much less common as these facilities are expensive to build and maintain.
• Public cold storage is characterized as a cold storage facility that’s owned and operated by a third-party logistics partner, also known as a 3PL company. Public storage warehouses receive, store, and ship the items on behalf of various companies. You can think of public cold storage warehouses like storage spaces, as there are multiple storage spaces that cater to the different needs of the companies they work with. Additionally, public cold storage warehouses also offer value-added services that include things like assembling items, placing inserts in packages, providing extended quality control, and so on. 

Now let’s talk about the variations in cold storage warehousing:

• Refrigerated containers: A refrigerated container is the most basic option for cold storage as it’s inexpensive and offers a small storage capacity for temperature-sensitive products. These cold storage containers are essentially shipping containers equipped with diesel-electric or grid-electric cooling units, generally maintaining a temperature range between -30°F and 70°F. They’re also customizable, meaning that they can take on different features such as floor types, indoor lighting, and remote temperature monitoring. They’re also mobile, which means they can be placed wherever your business needs.
• Blast freezers and chillers: Also known as shock freezers or flash freezers, blast freezers are used to rapidly chill products before they’re placed in long-term storage holdings — which means that blast freezers are considered an intermediary option between production and storage. These storage options use blower fans to quickly chill the air from 160°F to 40°F in just 90 minutes. This helps with several cold storage challenges, such as preserving flavor, quality, and nutrients, reducing bacterial growth, extending shelf life, and reducing the strain on conventional cold storage systems.
• Ultra-low temperature cold storage (UTL): UTLs rose in popularity during the COVID-19 pandemic as they’re necessary for safely storing vaccines. Aside from vaccines, UTLs are also used for storing medicines, blood, and tissue samples. This means they’re designed to function with optimal precision to preserve the most sensitive materials, and they’re often equipped with robust security systems to safeguard against theft as well as system failure. (UTLs are often referred to as pharmaceutical-grade cold storage).
• Cold rooms: Cold rooms are a common type of cold storage warehouse found in most commercial facilities and buildings today. This includes places like supermarkets, schools, hospitals, and even industrial areas that require specific temperatures to prevent spoilage or bacterial growth and contamination.
• Plant-attached cold storage: Plant-attached cold storage systems are typically located on the premises of the company that utilizes them — which means they’re private and attached to the facility. They’re often the perfect solution for companies that need to store their temperature-sensitive products for a long period of time and don’t want to waste money on long-term cold storage solutions outside of their building.
• Dedicated custom cold storage facilities: Dedicated custom cold storage facilities are designed to store perishable items, like large quantities of frozen foods. These facilities not only provide temperature control but monitoring and inventory management via specialized computer systems. The key to dedicated custom cold storage is automation, which cuts down on labor costs as there’s no need for manual transport from one warehouse to another. 

How to Choose a Cold Storage Warehouse

There are hundreds of cold storage warehouses in the US to choose from. The challenge is knowing which type is best for your business and which warehouse will serve your needs best.

Here are the criteria you’ll want to consider when choosing among the carious cold storage warehousing solutions:

• The distance between your production areas and customer bases
• The facility’s access to roads, railways, and airports
• The storage capacity you require and what the facility can offer
• Whether or not the facility has a reliable energy source
• The facility’s monitoring capabilities and practices
• Whether or not the facility has an inventory control system to keep track of everything that comes and goes out
• The facility’s reputation and credentials — credentials should include HACCP and FSMA certifications if they store food
• Whether or not they offer value-added services, like palletizing, kitting, labeling, shrinking, wrapping, packaging, etc
• The costs

In addition to the above criteria, you’ll also need to evaluate your business needs regarding production, scaling, transport, and the specific types of items you need to store.

Does Your Business Need Cold Storage Solutions?

Whether you’re starting a business or are looking to upgrade your cold storage solutions, it’s important to take the time to evaluate your needs and learn more about what’s out there. There are more cold storage facilities available today than there were just a few years ago, which means the perfect solution is out there and waiting for you.

Want to learn more about construction, cold storage warehousing, and industrial project management? Give the experts at APX Construction Group a call today, or check out our blog.

Building a commercial structure that incorporates substantial refrigeration elements is a complex task, and there’s a lot to consider. Whether it’s a cold storage warehouse, a supermarket with extensive frozen sections, or a food processing facility, it’s crucial to understand the significant components involved, effectively plan for them, and ensure that you have the right design and building team on board.

Cold storage may be as small as a reach-in cooler, or as large as hundreds of thousands of square feet of cooler and/or freezer space. Identifying what will be stored inside and knowing the logistics of the facility’s operations all contribute to the planning and construction of the building. Existing buildings can also feasibly be renovated to suit this purpose, with extra considerations and an adaptable build crew.

Building Structure & Exterior Considerations

The structure’s exterior is pivotal when integrating commercial refrigeration systems. The exterior skin, insulation systems, roofing, floor slab and ventilation must all be considered. Whether renovating or building new, the structure will heavily influence the longevity and energy efficiency of the building. Some of the components to consider include:

Insulation

Wall, roof, and floor insulation are vital to maintaining energy efficiency and preventing condensation. Insulation comes in many forms and must be evaluated to effectively resist moisture build up. 

Vapor Barriers

These prevent moisture infiltration, which can degrade insulation and cause structural issues. Vapor barriers of some form should be evaluated for areas such as walls, roof structure, windows and ceilings.

Doors and Entrances

Insulated doors, rapid roll-up doors, or air curtains can minimize temperature fluctuations. These systems can be manual or electronic with a variety of controls available depending on budget and desired functionality.

Flooring

Floors should be adequately insulated and able to handle low temperatures without cracking. Often made of concrete, freezer spaces typically need heating installed within and below the slab to prevent heaving and cracking.

Roof Structure

Coated steel and metal deck with insulation above the decking in lieu of below, or with insulated metal panels at the ceiling that resist corrosion are often the best solution to prevent moisture damage.

Height, Storage, and Fire Protection

Height Considerations

Vertical space can be utilized to maximize storage, but this may require specialized equipment and added safety measures. Higher ceilings can aid in better air circulation, ensuring uniform temperatures. Production strategies must be considered relative to storage solutions.

Storage Considerations

Efficient racking systems, optimized layouts, and multiple temperature zones might be necessary for facilities storing various products. Many buildings may have areas for bulk storage options with entrances into production areas, potentially with equipment that transports materials between them.

Fire Protection

Cold temperatures typically dictate constructing spaces with fire-resistant materials and specialized sprinkler systems designed for low temperatures. Racking will often dictate the placement of fire suppression piping and sprinkler heads, and temperature the type of system utilized. Local building codes must be reviewed and in compliance to achieve permits and inspection approvals.  

Electrical

Evaluate electrical load and confirm service size for new construction and renovations to accommodate the refrigeration equipment. Be sure to include any truck charging requirements for exterior refrigerated trailers at loading docks.

Commercial Refrigeration Components

Identifying and installing the right refrigeration systems is key to a successful commercial refrigeration project. As we discussed in a previous article, there are many components that make up a refrigeration system, all of which must be carefully considered when planning.

• Compressors, condensers, evaporators, and expansion valves are integral parts of the refrigeration cycle, working together to circulate refrigerant, absorb heat, and cool the desired space.
• Refrigeration fluids or gases are crucial to actually cooling the space. Their choice impacts efficiency, environmental concerns, and regulatory compliance. Common refrigerants include ammonia, CO2, and propane.
• Piping, controls, and automation components work in tandem to maintain efficiency, energy conservation, and optimal functionality of the refrigeration system. Controls and automations range from minimal to very complex, depending on the size and function of the building.  

When designing each commercial refrigeration system, consider how the product will be stored and transported. Product temperature will vary between users; some will keep product in temperature-controlled trucks, others will be at ambient temperature. Certain products are required to be maintained at a certain temperature while others will need to follow a rigid cooling schedule.  This may require temperature-controlled loading docks and dock seals to control the environment. Understanding how the building user will control product will allow you to create the most efficient build to meet the client’s needs.

Planning and Assembling the Right Team

Finding the right design and construction team is a crucial element of achieving the right space both on time and on budget. When it comes to cold storage and refrigerated spaces, there are a few things to consider when choosing a reputable general contractor:

• Hire experienced designers: Refrigeration is complex, and an experienced designer will ensure the system is efficient and compliant with local and federal codes, as well as food safety standards. Referrals from others who have created similar buildings can be a great place to start.
• Collaborate with a knowledgeable builder: Work with a reputable contractor during the design process to complete a thorough preconstruction process. With a design-build or similar collaborative design and construction process, owners can find optimal options for cost, schedule and longevity of the building.
• Involve a refrigeration engineer: These experts can propose various systems depending on how the building should function. They can ensure the system operates at peak efficiency and meets all technical requirements.
• Maintenance and support: Engage a construction team that brings trade partners on board with expertise in refrigeration systems. This team will include a full-service mechanical and electrical contractor. Ideally, the general contractor and trade partners have the capacity to provide ongoing operational support for the life of the building and/or business.  

Ensuring a Successful Project

Achieving a successful project usually means constructing a building on time, on budget, and meeting the end-use goals of the occupant(s). There are many means and methods to get from the idea of a building to the completion of it, with some more critical than others. These include:

• Clear communication: Regular meetings and updates will keep everyone on the same page. In a previous article, we discussed communication techniques and its importance to the construction process.
• Comprehensive preconstruction processes: Develop a clear budget, including contingencies for unforeseen expenses. Complete preconstruction investigations help prevent surprises both during and after the building is complete.
• Know the desired operational outcomes: A great design and construction team can help identify best practices for construction, but the business operator must know what items are must-haves vs. nice-to-haves with regards to the functionality of the building. Active participation during preconstruction by the end-user will help significantly.
• Regular review: Regular reviews and quality checks should be performed throughout the construction process by all team members, including the design team, specialty consultants, ownership and end users, in addition to the contractor’s teams.

Final Thoughts

Building a commercial refrigeration facility with significant components requires expertise, meticulous planning, and a comprehensive approach to integrate the refrigeration systems seamlessly with the building structure. It’s critical to evaluate not just the building process, but also how the building needs to operate in the short and long-term. Of equal importance, support for ongoing maintenance will increase the lifespan of the building.

If you’re contemplating a construction project involved cold storage, reach out our teams today.