1The Challenge
A major national grocery retailer needed to create a new -18 °C frozen product zone within an existing +5 °C chilled distribution centre, without decommissioning the chilled operation during construction. The new frozen zone needed to accommodate articulated trailer unloading, with two forklift-accessible connections to the chilled hall for cross-docking operations.
2Our Solution
Mercia Industrial designed and installed a ThermalShield insulated partition system using 100 mm foam-core panels to create the frozen zone enclosure, delivering a calculated U-value of 0.4 W/m²K. The two cross-docking connections were fitted with fast-acting insulated roller doors rated for temperatures down to -25 °C, with cycle times under 3 seconds to minimise thermal exchange during forklift passage. Installation was phased over 4 weekends to maintain continuous chilled operation, with the refrigeration contractors and Mercia's team coordinating their activities closely.
3The Outcome
The frozen zone achieved its target operating temperature of -18 °C within 36 hours of commissioning. Post-commissioning energy monitoring showed a 22% reduction in refrigeration running cost compared with the provisional assessment for an open-plan frozen area within the same building. The fast-acting roller door specification was validated — door opening events average 2.1 seconds, and the thermal analysis confirmed this was within the project's budget for incidental heat gain.
“The ThermalShield system has performed above specification. The 22% energy saving versus our baseline was better than projected, and the installation team's coordination with our refrigeration contractor made what could have been a very complex phased project run smoothly.”
— Head of Property, National Grocery Retailer
- Client
- Retail Distribution Warrington
- Location
- Warrington, Cheshire
- Industry
- Retail Distribution
- Product
- ThermalShield