Pharmaceutical Manufacturer in North Wales

Detailed heatload calculations were undertaken for the new freezer and our equipment was selected based the results.

The freezer was designed to operate at -25°C to provide a buffer in case of issues or excessive door openings.

The new walk-in freezer was built by our coldroom contractors Heritage Hygienic Ltd and was approximately 16.00m long x 14.00m wide, with a height of 2.70m.

To form the floor to the freezer, we supplied and installed a 25mm modular heater mat with transformer controls, 100mm thickness LPC approved PIR core panel, with 12mm marine ply ready for a low temperature resin finish by others, including all necessary flashings, covings, anti-fungicidal silicone, and fixings.

The main access to the new walk-in freezer was via a 1.0m x 2.0m pedestrian door and a 1.5m x 2.0m trolley door. The doors were operated via a Fermod auto door kit, with both horizontal and vertical safety sensors. The doors automatically close after an adjustable pre-set amount of time.

There was also an emergency door installed at the side of the freezer, along with a door switch installed on each door to alarm locally after a pre-set and adjustable time.

To serve the above enclosure, we selected and installed three independent, direct expansion refrigeration systems operating on R449A refrigerant, utilising fully housed packaged condensing units and ceiling mounted evaporator coolers.

Each installed system was capable of 18.18kw of refrigeration duty, providing a total duty of 54.54kw under the conditions specified.

The three systems ran together, with any two capable of maintaining the desired room temperature in the event of a failure to one of the systems or whilst another

 Is defrosting. This provided a fully flexible run and standby operation for the room.

The condensing units were manufactured by Copeland, and each contained a Copeland Stream compressor, integral condenser fans, fan speed control, filter drier, sight glass, oil separator, PRV and automatic safety controls. In the event of a fault the condensing units send a fault signal to the internal control panel.

The condensing units were positioned externally on concrete pads in a designated plant area.

The evaporator coolers were of copper tube/aluminium fin construction and manufactured by Searle. Defrosting of the evaporators and drip trays was via electrical defrost heaters installed within the coolers.

An IP65 control panel housing ID974 Eliwell plus controllers was installed to serve each system along with all breakers, contactors, and run/fault lamps was installed within the Airlock Area. 

Volt free contacts were provided within our controls to interface with the clients BMS alarm system.

Energy efficient LED lighting was installed by our electrical contractors PDR Electrical Ltd and operated via PIR sensors, providing a minimum lighting level of 300 lux. Emergency lighting was also installed.