Pharmaceutical Cold Room Extension

ICE designed and installed a completely independent cold room extension, providing storage for an additional 30 pallets. The new cold store was constructed on the first floor mezz area of the depot, designed to operate reliably between 2°C and 8°C, with a set point of 5°C, in line with MHRA storage guidelines.

To allow seamless workflow and visual continuity, two large openings were created in the adjoining wall between the existing and new cold rooms. These openings made it easy for operatives to transfer goods, giving the perception of one large cold space. However, each opening was fitted with heavy-duty sliding doors, which could be quickly shut in the event of a failure in the existing system, ensuring the integrity of the new cold store was protected at all times.

Key elements of the solution included:

• Full demolition and removal of old workspaces to prepare the installation area.
• Construction of a new cold room structure, with 80mm CFC-free polyurethane insulated walls and 100mm thick ceilings, finished in white food-safe PVC-coated galvanised steel.
• A new insulated modular floor, reinforced with exterior-grade plywood and finished in 6WL patterned slip-resistant stainless steel.
• Installation of one automatic sliding access door and one personnel hinged door with a vision panel, replacing the original double door with a blocked-up section for better thermal control.
• Integrated LED lighting, mains power connections, and full electrical works.

The refrigeration system was designed with dual run/standby configuration, ensuring uninterrupted operation 24/7, 365 days a year. Two direct expansion systems were installed, each capable of handling the full load of 14.94kW, delivering a combined total duty of 29.88kW. These used R449A refrigerant, selected for its improved energy efficiency and lower global warming potential (GWP) compared to the phased-out R404A.

Each system consisted of:

• A Danfoss Optyma Plus packaged condensing unit with scroll compressor, integral condenser, fans, and onboard diagnostics.
• A Kelvion evaporator cooler with electric defrost heaters for efficient frost management.
• All pipework insulated with fire-retardant Armaflex and supported with Armafix or Hydrozorb clamps for safety and durability.

The equipment was installed by ICE’s in-house team, led by on-site supervisor Daniel Bush and managed by Head of Projects Lee Hopkins. The project was completed and handed over in March 2025, including commissioning, “as built” drawings, and all required O&M manuals.