Keeping Your Warehouse Cool: A Guide To Improving Thermal Comfort And Productivity

Properly managing the temperature of your facility is not only important for maintaining the integrity of your products, it’s also important for maintaining your employees’ health, safety and productivity. Extreme temperatures, whether they’re hot or cold, can negatively impact your team’s efficiency and pose potential risks to their well-being. Plus, the Health and Safety at Work Act 2015 requires employers to ensure the health and safety of their workers and provide an environment without risks, as far as is reasonably possible, meaning your business could be liable for not maintaining proper temperature control in your facility.

Luckily, we have a few solutions to help make sure your warehouse stays comfortable, even in the peak heat of summer. But before we get into the solutions, let’s talk about thermal comfort.

What is ‘thermal comfort’ and why is it important?

According to WorkSafe New Zealand, thermal comfort describes whether a person feels too hot, too cold, or just right. While it may seem obvious, people aren’t usually at their most productive if they’re too hot or cold and prolonged exposure to temperatures that are too high or low can impact their health.

WorkSafe has identified the following temperature ranges as a guide to maintaining thermal comfort. These temperatures will be comfortable for most people in an indoor environment.*

Summer Winter
Sedentary Work         19-24°c 18-22°c
Physical Work         16-21°c 16-19°c

*These values assume:

  • Workers are wearing seasonally appropriate clothing
  • The air speed is about 0.1–0.2 metres per second (without creating a draught where sedentary work occurs)
  • Humidity levels are normal (40-70%)
  • Workers are not directly exposed to any radiant heat sources

So I think we can all agree that properly managing the temperature of your facility is good for everyone – but the real question is how?

Are heating and cooling systems the answer?

The obvious solution many people turn to for maintaining thermal comfort is a heating and/or cooling system. While these are an important piece of the puzzle, in large areas such as warehouses, maintaining consistent temperatures is incredibly difficult. In addition to a heating/cooling system, large areas require good ventilation, insulation and layout planning to properly maintain thermal comfort.

That’s where HVLS Industrial Fans Come In

HVLS fans are designed to circulate the air in your facility more efficiently, moving large volumes of air at an optimised low speed to help maintain a consistent temperature across your facility. They create an airspeed of only 3-5 km/h but due to their size (up to 7.5m in diameter), they still move large amounts of air without creating a draught.

The top 5 benefits of HVLS Industrial Fans

1. Keeps things cool in summer

As we’ve already discussed, an HVLS Industrial Fan can lower the overall temperature of your facility by 3-6 degrees. And due to their low speed, they don’t create uncomfortable draughts. They support existing air conditioners by moving the air around more efficiently so the air conditioning system itself doesn’t have to work as hard, creating a more comfortable environment for your employees.

2. Keeps things warmer in winter

While it may seem counterintuitive, HVLS Industrial Fans also help keep your facility warmer in the winter, too, by minimising the stratification of the air. Stratified air is the cool, dense air that sinks, pushing warm air up. HLVS fans disrupt this by cycling the warm air down.

3. Enhances air quality

Poor air circulation can not only cause temperature differences throughout the facility, putting products at risk of spoilage, it can also encourage bacteria growth and mould in some areas. HVLS Industrial Fans move a high volume of air consistently through the facility, reducing these risks and keeping your staff healthy.

4. Combats moisture and humidity

Similar to the way they enhance air quality, HVLS Industrial Fans also help combat moisture and humidity by moving high volumes of air around the facility. This keeps moisture in the air from settling onto surfaces, which if not dealt with can lead to product damage, rust on equipment or bacteria growth.

5. Keeps staff comfortable

As we discussed earlier, thermal comfort is an important part of Health and Safety in the workplace and as part of the Health and Safety at Work Act 2015, you can be held responsible for not maintaining proper thermal comfort. HVLS Industrial Fans give your heating and cooling systems a boost to maintain a consistent temperature and keep the thermal comfort of your facility in check.

As you can see, investing in a proper system to help maintain temperatures in your facility is good for business in several ways. An efficient system keeps your people safe, your products safe, and saves you money on excessive energy waste. While having the proper heating and cooling equipment is important, an HVLS Industrial Fan could be the missing piece in helping you maintain thermal comfort.

Talk to our experts today and find out if HVLS Industrial Fans are right for your facility.

The Science of Preventing Condensation in Cold Stores

In the world of cold storage and freezer facilities, one of the most significant challenges is managing condensation and ice formation, because these issues lead to safety hazards, operational inefficiencies, and increased energy costs. Understanding the science behind these phenomena and knowing how to mitigate these risks is crucial.

 

Understanding the Key Components

Why does condensation even occur in cold storage environments?

It all boils down to two things: moisture in the air (humidity) and temperature differences. When warm, humid air hits a cold surface which is below the dew point, like the walls or doors in your coldstore, it cools down, and just like a cold drink on a warm day, this cooling causes water vapour in the air to turn into liquid, creating condensation.

What is the dew point?

The dew point is the temperature at which air becomes fully saturated with moisture and starts to condense. It’s the temperature at which the air needs to be cooled to for water in the vapour to condense. If the surface temperature inside your coldstore is below this dew point, voilà, you’ve got condensation. And this isn’t just a minor inconvenience; it can lead to all sorts of problems like mold, product damage, and slip hazards.

Insulation and Its Importance

In cold storage, the goal is to maintain a consistently low surface temperature on the internal sides of these surfaces to ensure the ambient temperature remains stable. This stability is crucial for the preservation of stored goods.
Insulation plays a pivotal role in maintaining these surface temperatures. It works by reducing the heat transfer between the inside of the cold storage and the external environment. In the context of a cold storage door, effective insulation means that the internal surface of the door remains close to the desired storage temperature, even if the external surface is exposed to much higher temperatures.

R-Value: Measuring Insulation Effectiveness
The R-value is a measure of the thermal resistance of an insulating material. The higher the R-value, the better the material is at insulating. In cold storage doors, a high R-value is desirable as it indicates that the door is effective in resisting heat flow. This means less energy is required to maintain the internal temperature of the cold storage, leading to energy efficiency and cost savings.

U-Value: Understanding Overall Heat Transfer
The U-value, on the other hand, measures the overall heat transfer coefficient of a material. It takes into account not only the insulation but also the conductive and convective properties. In simple terms, the U-value indicates how well a building element, like a door, can transfer heat. A low U-value is ideal for cold storage doors as it signifies lower heat transfer, thus better insulation and temperature control.

Mitigation Strategies

Although insulation helps to prevent heat transfer, in areas where there is a high temperature differential it is often insufficient to prevent the external surface temperature of the door from dropping below the dew point. This leads to condensation, which can be problematic for both the integrity of the stored goods and the facility’s structure. In such scenarios, additional measures need to be considered to address this challenge effectively.

Mitigating Cold Surfaces: Using heating, insulation, or thermal breaks to increase surface temperatures.

Insulation Improvement
Enhancing the door’s insulation can help to keep the surface temperature above the dew points.

Thermal Breaks
Thermal breaks are often an essential component in cold storage doors. They’re materials or methods that reduce the transfer of temperature across a surface. By incorporating thermal breaks into your coldstore design, you can keep those cold surfaces from getting too cold and reaching the dew point. Enhancing or adding thermal breaks can improve the door’s overall thermal performance, helping to keep the external surface temperature above the dew point, and eliminating the possibility of condensation forming.

Heated Door Surfaces
In some cases, particularly in very humid environments or where the temperature differential is significant, installing doors with heated surfaces might be necessary. These doors have built-in heating elements that keep the external surface temperature above the dew point, thereby preventing condensation.

Mechanical Dehumidification: Using air conditioning units to remove moisture from the air.
Using dehumidifiers in the vicinity of the cold storage doors can reduce the moisture content in the air, thereby lowering the dew point. This makes it less likely for condensation to occur on the door surface.

Improving Air Circulation: Enhancing airflow to prevent localized humid conditions and re-evaporate any formed condensation.
In scenarios where the external surface temperature of a cold storage door is below the dew point, leading to condensation, incorporating fans or enhancing air movement on the warmer side (outside the cold storage) can be an effective strategy. This approach works by altering the microclimate around the door, dispersing moist air, and increasing evaporation rate, reducing the likelihood of condensation formation.

Calculating for Success

So, how do we determine if a door or wall is going to do its job in preventing condensation? This is where the U-value comes in.
Here’s a simple method we use to gauge the effectiveness of a door or wall in a coldstore. Consider the dew point on the warm side of the door (you can calculate this using a Pyschrometric Chart). Using the U-value of the door, you can calculate the potential reduction in surface temperature on the other side. If the calculated temperature is above the dew point, you’re fine. If not, you might need to consider additional measures like increasing airflow to prevent condensation.

The Example Scenario
Consider a freezer set at -20°C, opening into a chilled environment at 10°C. The relative humidity (RH) inside the freezer is 50%, and on the warm side, it’s 70%.

Step 1: Calculate the U-Value
Given the R-value of the door (4 m²K/W), the U-value is calculated as:
U−value = 1/R−value
1/4 m²K/W=0.25 W/m²K

Step 2: Calculate Surface Temperature of the Door on the Warm Side
We determine how cold the door surface gets using the formula: Surface Temperature=Internal Temperature+(Temperature Difference×U-value)
In our case, this calculates to -12.5°C.

Step 3: Calculate Dew Point on the Warm Side
Similarly, we calculate the dew point for the 10°C environment with 70% RH, which comes to 4.78°C.

Step 4: Compare Surface Temperature with Dew Points
Condensation occurs if the door’s surface temperature falls below the dew point. Here, the surface temperature of -12.5°C is lower than the dew point on the warm side (4.78°C), indicating a risk of condensation and ice formation.

Understanding and managing condensation and ice formation in cold storage environments requires a combination of thermodynamic knowledge, environmental control, and effective facility management. By applying these principles and strategies, we can help you mitigate the risks associated with condensation and ice, ensuring safe, efficient operations and the integrity of stored goods. Regular assessments and proactive measures are essential for maintaining optimal conditions in these critical environments.

Reach out to Ulti Group for support in your cold storage environment.

 

Enquire Now >

Considering New Doors For Your Cold Storage Facility? Partner With The Experts

why you should choose Ulti Group for your cold storage door needs

why you should choose Ulti Group for your cold storage door needsWhen it comes to getting a door system for your cold storage area, you need an expert who’s got your back. At Ulti Group, what matters to you, matters to us, and we’ve got the experience to make sure you get the perfect door, installed exactly right, that will protect your people, products and profits.

Our Ultimate Guide: Why You Should Choose Ulti Group For Your Cold Storage Door Needs gives you all the details about who we are and our approach to helping you protect what matters, so you can make sure to partner with a company you trust.

We Are New Zealand’s Most Trusted Industrial Door And Dock Loading System Provider.

Ever since Ulti Group was founded in 1993, we have been protecting what matters most to our customers. With innovative door systems, loading systems, and warehouse safety solutions installed and maintained across a wide range of industries, improving operational efficiency, increasing productivity, and reducing both cost and risk at facilities right across New Zealand.

What does that mean for you?

Well, we partner with you to build smarter, safer access solutions that protect what matters most: your people, products and profits. As you know, getting a door for your cold storage area is about more than just picking any old door out of a line-up—it’s about getting to know your location, understanding your needs, and identifying any areas of concern.

Our experts take you through the whole process, lending their experience to make sure you get the right system, right from the start, with a full range of solutions for any industry.

Learn more about our process and see for yourself why you should partner with Ulti Group for your cold storage door needs in our Ultimate Guide. Click the link below to download your copy or, if you’re ready to take the next step and update your door systems, talk to one of our experts for a free consultation.

 

Enquire Now >

Make Sure You Get The Right Door For Your Cold Storage Facility With Our Ultimate Guide

choosing the right the door for your cold storage area

choosing the right door for your cold storage areaWhen you have the right door in place, it helps protect your people, products and profit with easy, safe access, good temperature regulation, and high levels of efficiency. But it’s not as simple as just splashing out the most high-tech door on the market. The door that’s right for another business might not be the door that’s right for you.

Our Ultimate Guide: Choosing The Right Door For Your Cold Storage Area will give you all the details you need to make sure you get the right door.

The guide covers the risks related to NOT having the right door for your cold storage area, such as safety hazards or risk of contamination, as well as what things you should consider when weighing up your door options. It also includes a helpful overview of our range of freezer and coolroom doors and some tips on how to take care of your doors so they last longer and are more efficient.

Click the link below to download your copy or, if you’re ready to take the next step and update your door systems, talk to one of our experts for a free consultation.

 

 

Enquire Now >

Save Money In Your Cold Storage Facility With Our Ultimate Guide

maximising your energy efficiency in cold storage areas

maximising your energy efficiency in cold storage areasAny industry that utilises freezer and coolroom storage areas face the problem of energy efficiency. From dairy and food processing applications to supermarkets and other food or product storage, maintaining temperatures and keeping products safe relies on having energy efficient systems in place. The Ultimate Guide: Maximising Your Energy Efficiency in Cold Storage Areas will take you through everything you need to know to protect your people, products and profits.

In it you’ll find details on the costs of poor efficiency, including rising energy costs, increased maintenance issues and higher carbon emissions. It also covers the most common problem areas and how to identify them. Things like gaps around the edge of your doors or ice build-up can have a big impact to your bottom line.

But it’s not all bad! The guide also outlines our top energy-saving tips, the types of doors available to suit different areas and applications, and what to do with your new-found information about energy efficiency.

Click the link below to download your copy, or if you’re ready to take the next step and update your door systems, talk to one of our experts for a free consultation.

 

Enquire Now >

Protect Your Sustainability Goals With The Right Door

dock-shelter-dock-seal-ultigroup-industrial-doors-dock-loading-systems-sustainability-commercial-doors-industrial-doors

Environmental sustainability has become an important and unavoidable part of how the world does business.  As sustainability becomes increasingly important in the business world, companies are looking for ways to reduce their carbon footprint and operate in an environmentally responsible manner. If you care about the environment and your bottom line, you need to pay attention to your commercial cooler and freezer doors. These doors are not just a way to access your refrigerated goods, they are also a key factor in how much energy you use and how much money you spend.

Commercial coolers and freezers are vital for many businesses, from supermarkets to labs and factories, but they also consume a lot of energy, which means higher bills and more greenhouse gas emissions. That’s why you need doors that are well-insulated and properly sealed so that you can keep the cold air in and the warm air out.

blue-high-speed-door-freezer-coolroom-air-door-commercial-door-ultigroup

By choosing the right doors for your cooler and freezer storage, you can enjoy many benefits, such as:

Lower Energy Costs and Improved Sustainability.

Energy-efficient doors help maintain a stable temperature inside the cooler or freezer, which means less work for the refrigeration system and less energy wasted. This can save you up to 30% on your energy bills. In addition to energy savings, the right door can also improve your company’s sustainability performance by reducing your carbon footprint. The use of energy-efficient doors can help to reduce greenhouse gas emissions associated with energy consumption, which is a significant contributor to climate change.

Longer Equipment Lifespan and Lower Maintenance

Energy-efficient doors also prevent temperature fluctuations and ice buildup that can damage the refrigeration system and cause breakdowns. This can extend the life of your refrigeration equipment and reduce the need for costly repairs and replacements. The durability of the door is also an essential factor to consider when investing in commercial cooler and freezer doors, selecting the right door will reduce the need for excessive maintenance or frequent replacements.

Protect Product Quality and Safety

Energy-efficient doors also protect your products from spoilage and contamination by keeping them at the optimal temperature and preventing air leakage, and ice buildup. This can improve your product quality and reduce waste. All this while improving your site safety standards, by eliminating dangerous ice build-up on the ceiling, and the need for frequent defrost cycles to de-ice the freezer.

 

dock-levellers-ultigroup-industrial-doors-dock-loading-systems-hydraulic-dock-levellers

At Ulti Group, we have a range of cooler and freezer door systems that are designed to be energy-efficient, durable, and safe. We also have new innovative solutions like the Ulti Air Door that create an invisible barrier of air to keep the cold in and the heat out. Whether you need sliding doors, swing doors, or roll-up doors, we have the right solution for your business, and we’re always developing new innovative solutions to minimise our environmental impact while maximising your productivity.

Don’t let your old and inefficient doors continue to cost you money and harm the environment. Get in touch for a free, no-obligation consultation with our team of experts and find out how we can help you upgrade to energy-efficient doors that protect your sustainability goals.